This manual covers the 250 EXC, 400 EXC, 450 EXC, 520 EXC, and 525 EXC models produced between 2000 and 2003. These motorcycles, built on the robust LC4 platform, are renowned for their powerful single-cylinder engines, advanced WP suspension, and exceptional off-road prowess, making them highly sought after for enduro riding and demanding terrain. The heritage in motorsports is evident in the engineering of these machines, which are designed for durability and performance in competitive off-road environments. This comprehensive service and repair manual provides detailed instructions for maintaining and repairing all listed EXC models. It covers a wide range of systems, including engine overhaul, fuel and ignition systems, transmission and clutch, suspension, brakes, and the electrical system. With over 500 pages of information, this English-language guide offers routine maintenance procedures, troubleshooting guides, component rebuilds, torque specifications, and special tool requirements, ensuring owners and technicians can effectively service these high-performance motorcycles. 🏷️ Basic Information Identification Make: KTM Model: 250 EXC, 400 EXC, 450 EXC, 520 EXC, 525 EXC Model Variant: All EXC Models Model Years Covered: 2000, 2001, 2002, 2003 Codes Chassis Codes: LC4 Platform (Specific codes vary by exact model and year) Engine Codes: LC4 Engine Variants (e.g., 250, 400, 450, 520, 525 displacements) 👋 Introduction Market Position Market Segment: High-performance off-road motorcycles (Enduro/Dual-Sport). Target Audience: KTM owners, independent repair shops, DIY enthusiasts. Competitive Analysis Competitors During Era: Honda CRF, Yamaha WR, Suzuki DR-Z, Kawasaki KLX, Husqvarna TE series. Key Features Key Manual Selling Point: Provides owners and technicians with the detailed, accurate information needed to maintain and repair these rugged KTM LC4 models. Vehicle Reputation: Known for their powerful engines, robust chassis, and off-road prowess, often favored for enduro racing and demanding terrain. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for all listed KTM EXC models from 2000-2003. Page Count Estimated Page Count: 500+ Manual Type Manual Type: Service & Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly of engine components. Fuel System: Carburetor tuning, cleaning, rebuilding; fuel pump diagnostics (if applicable); fuel tank and lines. Ignition System: Ignition coil testing, spark plug specifications, CDI unit diagnostics. Transmission And Clutch: Gearbox inspection, repair, clutch adjustment, replacement of friction plates. Suspension Systems: Front fork (WP USD) disassembly, seal replacement, oil level and type specifications. Rear shock absorber inspection and service. Braking System: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding procedures, disc inspection. Electrical System: Wiring diagrams, component testing (lights, indicators, starter, battery), troubleshooting electrical faults. Cooling System: Radiator inspection, coolant type and capacity, hose replacement, fan operation (if equipped). Chassis And Frame: Frame inspection for damage, steering head bearing service, swingarm lubrication and bearing check. Bodywork And Plastics: Fairing removal and installation, seat maintenance, fuel tank mounting. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, air filter cleaning. Troubleshooting Guides: Step-by-step diagnostic procedures for common and complex issues. Component Rebuilds: Detailed instructions for rebuilding carburetors, brake calipers, water pumps, etc. Torque Specifications: Essential torque values for critical fasteners across all systems. Special Tool Requirements: Identification of specific tools needed for certain repair procedures. Technical Depth Depth Of Coverage: In-depth mechanical and electrical repairs, covering everything from basic servicing to complete engine rebuilds and chassis overhauls. Diagnostic Capabilities: Advanced troubleshooting techniques, symptom-to-cause analysis. 📊 Manual Specifications File Format File Format: PDF Searchability: Text-searchable PDF for quick information retrieval. Print Quality Print Quality: High-resolution scans with clear diagrams and text, suitable for printing. 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, liquid-cooled (LC4). Bore X Stroke 250: 72 mm x 60 mm (approximate) Bore X Stroke 400: 84 mm x 72 mm (approximate) Bore X Stroke 450: 95 mm x 63.4 mm (approximate) Bore X Stroke 525: 97 mm x 70.6 mm (approximate) Compression Ratio General: Approx. 11.0:1 - 12.5:1 (varies by displacement) Valve Actuation: SOHC (Single Overhead Camshaft), 4 valves Performance Horsepower 250: Approx. 30-35 HP Horsepower 400: Approx. 40-45 HP Horsepower 450/525: Approx. 45-55 HP Torque General: Substantial torque output, especially in 450/525 models, optimized for off-road traction. Fuel System Carburetion: Keihin flatside carburetors (e.g., PWK 39, 39.5, 41mm, varies by model/year). Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/95 AKI. Lubrication System Oil Type: JASO MA certified motorcycle specific 4-stroke engine oil. Oil Capacity: Approx. 1.5 - 2.0 liters (varies by model, check manual for exact amount with filter change). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh manual transmission. Clutch Type: Wet multi-plate clutch. Final Drive: O-ring sealed chain drive. Features Transmission Design: Robust design for off-road use, with gear ratios tailored for strong low-end and mid-range power delivery. 📐 Dimensions Exterior Frame Type: Chromoly...