This document pertains to the 250/450/525 SX, MXC, and EXC models from the 2004 production year. These high-performance off-road motorcycles are celebrated for their powerful single-cylinder engines, robust chassis, and capable suspension systems, making them ideal for competitive motocross and enduro riding. An Austrian manufacturer with a strong heritage in off-road racing, engineered these bikes to deliver exceptional power delivery and handling, often achieving championship status in their classes. The models are characterized by their reliable LC4 engine derivatives, 6-speed manual transmissions with hydraulic clutches, and advanced WP suspension components. This parts catalog serves as an indispensable resource for owners, technicians, and enthusiasts. It provides detailed identification of all engine components, featuring exploded views crucial for accurate disassembly, reassembly, and parts lookup. The manual covers a wide array of engine parts, including cylinder, piston, crankshaft, valves, camshaft, carburetor, clutch, and gearbox components, as well as related ancillaries like the exhaust and cooling systems. Its comprehensive coverage ensures that users can efficiently identify correct OEM part numbers for maintenance and repair, thereby preserving the performance and longevity of their 250, 450, or 525 SX, MXC, or EXC motorcycles. 🏷️ Basic Information Identification Make: KTM Model: 250/450/525 SX, MXC, EXC Year: 2004 Product Type: Engine Parts Book Codes Chassis Codes: SX: 2004; EXC: 2004; MXC: 2004 Engine Codes 250: Likely LC4 derivative or similar single-cylinder off-road engine Engine Codes 450: Likely LC4 derivative or similar single-cylinder off-road engine Engine Codes 525: Likely LC4 derivative or similar single-cylinder off-road engine 👋 Introduction Market Position Market Segment: High-performance off-road motorcycles (Motocross and Enduro) Competitive Analysis Competitors: Yamaha YZ series, Honda CRF series, Suzuki RM/DRZ series, Kawasaki KX series, Husaberg, Husqvarna. Key Features Vehicle Attributes: Powerful single-cylinder engines, robust chassis, capable suspension, designed for competitive off-road riding and racing. Manual Value Proposition Utility: Essential for owners and technicians performing engine maintenance, repairs, or parts replacement to ensure accuracy and efficiency. Target Audience: KTM Owners, Independent Repair Shops, Enthusiasts 📋 Manual Details Coverage Areas Coverage Scope: Engine component identification and exploded views Vehicle Variants Covered: KTM 250 SX, 450 SX, 525 SX, 250 MXC, 450 MXC, 525 MXC, 250 EXC, 450 EXC, 525 EXC Page Count Estimated Page Count: Typically 100-200 pages for this type of document, but specific count not provided. Manual Type Type: Parts Catalog / Parts List / Illustrated Parts Manual Language Language: English (standard for KTM manuals of this era) Format Format: Printed (implied by sales context, but could be PDF) 📖 Manual Coverage Systems Covered Engine Assembly: Cylinder, Piston, Crankshaft, Connecting Rod, Valves, Camshaft, Carburetor (if applicable), Ignition components (related to engine), Oil pump, Clutch assembly, Gearbox components. Engine Ancillaries: Exhaust system components (header, muffler), cooling system components (radiator, hoses if applicable), air filter housing and related. Procedures Included Disassembly Identification: Identification of individual parts for disassembly and reassembly. Assembly Identification: Identification of individual parts for assembly and reassembly. Parts Lookup: Crucial for identifying correct replacement parts. Technical Depth Depth: Detailed identification of OEM part numbers, quantities, and relationships between components. 📊 Manual Specifications File Format File Format: N/A (assuming printed copy) Print Quality Print Quality: Expect professional-quality printing with clear illustrations and text. (Standard for OEM manuals). Binding Type Binding: Likely perfect bound or saddle-stitched for a printed manual. Paper Type Paper Quality: Durable paper stock suitable for workshop environments, often glossy or semi-gloss for illustrations. ⚙️ Engine Specifications Primary Engine Engine Type 250: Single-cylinder, 4-stroke (likely OHC or DOHC, liquid-cooled) Engine Type 450: Single-cylinder, 4-stroke (likely OHC or DOHC, liquid-cooled) Engine Type 525: Single-cylinder, 4-stroke (likely OHC or DOHC, liquid-cooled) Bore X Stroke 250: Specific data not provided, but typically around 76mm x 54.8mm for similar displacements. Bore X Stroke 450: Specific data not provided, but typically around 95mm x 63.4mm for similar displacements. Bore X Stroke 525: Specific data not provided, but typically around 97mm x 70.5mm for similar displacements. Performance Horsepower 250: Estimated 40-45 HP (stock) Horsepower 450: Estimated 50-55 HP (stock) Horsepower 525: Estimated 55-60 HP (stock) Torque Peak 250: Estimated 25-28 lb-ft Torque Peak 450: Estimated 33-36 lb-ft Torque Peak 525: Estimated 36-40 lb-ft Fuel System Fuel Delivery 250: Carburetor (likely Keihin FCR MX series) Fuel Delivery 450: Carburetor (likely Keihin FCR MX series) Fuel Delivery 525: Carburetor (likely Keihin FCR MX series) Fuel Type: Unleaded gasoline (91 octane or higher recommended) 🔧 Transmission Standard Transmission Type: 6-speed manual gearbox Optional Transmission Options: N/A (standard for this model) Features Clutch Type: Wet multi-plate clutch (hydraulic actuation) Gear Ratios: Specific ratios not provided, but designed for aggressive off-road use. Transmission Fluid Type: KTM recommends specific motorcycle gear oil or high-quality JASO MA certified transmission fluid. 📐 Dimensions Exterior Wheelbase: Varies by model (SX, EXC, MXC) but typically around 57-59 inches. Seat Height: Varies by model (SX, EXC, MXC) but typically around 37-39 inches. Weights Dry Weight...