This manual covers the SX and EXC series motorcycles produced between 2000 and 2007, featuring the RFS engine platform across various displacements including 400cc, 450cc, and 525cc models. The renowned 'Ready to Race' philosophy is evident in these high-performance off-road machines, designed for competitive motocross and demanding enduro riding. These models are celebrated for their powerful engines, agile handling, and robust construction, making them a popular choice for both professional racers and dedicated off-road enthusiasts seeking exceptional performance and rider engagement. This comprehensive factory service repair workshop manual provides detailed instructions for maintaining and repairing your SX or EXC motorcycle. It covers all essential systems, including engine mechanicals, fuel and ignition systems, cooling, transmission, suspension, braking, and electrical components. The manual includes step-by-step procedures for routine maintenance, engine rebuilds, suspension servicing, and electrical diagnostics, along with troubleshooting guides and technical specifications. Its thorough coverage ensures owners and technicians can effectively perform all necessary service and repair operations, maximizing the longevity and performance of the vehicle. 🏷️ Basic Information Identification Make: KTM Model: SX / EXC Product Name: KTM 25 400 450 525 SX EXC Motorcycle 2000-2007 Service Repair Workshop Manual Pdf Codes Engine Codes Implied: RFS (Ready For Suspension) engine platform across various displacements 👋 Introduction Market Position Segment: High-performance off-road motorcycles (Motocross and Enduro) Target Audience: Competitive racers, serious off-road enthusiasts, professional mechanics specializing in KTM motorcycles. Competitive Analysis Competitors: Yamaha YZ/WR series, Honda CRF/XR series, Suzuki RM/DRZ series, Kawasaki KX/KLX series. Key Features Vehicle Philosophy: KTM's 'Ready to Race' philosophy emphasizing performance, power, and rider engagement. Manual Benefit: Enables owners to perform complex maintenance and repairs, reducing reliance on dealerships and extending the life of the vehicle. 📋 Manual Details Coverage Areas Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Model Variants Covered: SX (Motocross), EXC (Enduro/Cross-Country) Engine Displacements Covered: 250cc (implied, common in SX line), 400cc, 450cc, 525cc Page Count Estimated Page Count: High (typically 300-600+ pages for comprehensive factory manuals) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly and reassembly of engine, cylinder head, valve train, piston, connecting rod, crankshaft, transmission, clutch, lubrication system. Fuel System: Carburetor (Mikuni, Keihin) tuning, cleaning, and overhaul; fuel pump (if applicable); fuel tank and lines. Ignition System: Ignition timing, CDI unit, stator, ignition coil, spark plug specifications and testing. Cooling System: Radiator, coolant hoses, water pump, thermostat specifications and maintenance. Transmission And Drivetrain: Gearbox inspection, repair, and adjustment; clutch operation and maintenance; chain and sprockets; final drive. Suspension Front: Front fork (WP) disassembly, reassembly, oil types, levels, pressure adjustments, seal replacement, and internal component servicing. Suspension Rear: Rear shock absorber (WP) servicing, linkage maintenance, spring preload adjustment, damping adjustments. Braking System: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding and specifications, rotor inspection. Electrical System: Wiring diagrams, battery maintenance, lighting system, starter motor, switches, fuses, and troubleshooting electrical faults. Frame And Bodywork: Frame inspection, subframe, handlebars, seat, plastics, exhaust system removal and installation. Wheels And Tires: Wheel bearing inspection and replacement, spoke tensioning, tire pressure recommendations, rim maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning, spark plug checks, valve clearance checks. Troubleshooting: Diagnostic flowcharts, common problems and their solutions, symptom-based troubleshooting guides. Engine Rebuild: Detailed instructions for top-end and bottom-end engine rebuilds, including torque specifications and clearances. Suspension Servicing: Step-by-step guides for fork and shock absorber overhaul, including fluid types and quantities. Electrical Diagnostics: Schematics, testing procedures for electrical components, fault finding for ignition and charging systems. Chassis And Bodywork Repair: Instructions for frame alignment checks, body panel removal/installation, exhaust system mounting. Technical Depth Depth Of Coverage: Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts. Includes all aspects from routine maintenance to complete engine and chassis overhauls. Diagnostic Capabilities: Detailed diagnostic procedures, troubleshooting tables, and electrical schematics for accurate fault identification. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text-based PDF (assuming digital reproduction from original source) Print Quality Digital Quality: High-resolution scans or digital native, ensuring clarity of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled (RFS engine platform) Bore X Stroke 400: Approx. 84mm x 72mm (Typical for 400cc RFS) Bore X Stroke 450: Approx. 95mm x 63.4mm (Typical for 450cc RFS) Bore X Stroke 525: Approx. 95mm x 72mm (Typical for 525cc RFS) Bore X Stroke 250: Approx. 76mm x 54.8mm (Typical for 250cc 2-stroke, or specific 4-stroke variants) Performance Horsepower 450: Estimated 50-55 HP (Varies by model year and tuning) Torque 450: Estimated 45-50 Nm (Varies by model year and tuning) Fuel System Carburetor...