🏷️ 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 250: Approx. 230-240 lbs (104-109 kg) Dry Weight 450: Approx. 240-250 lbs (109-113 kg) Dry Weight 525: Approx. 245-255 lbs (111-116 kg) Fuel Tank Capacity: Typically 2.5-3.5 gallons (9.5-13 liters) 🛡️ Safety Features Ratings Safety Certification: Not applicable in the traditional automotive sense for off-road motorcycles; designed for off-road use only. Active Features Braking System: Hydraulic disc brakes (front and rear) with Brembo calipers. Suspension System: High-performance, adjustable upside-down front forks (WP Suspension) and monoshock rear suspension (WP PDS or similar). Passive Features Frame Construction: Chromium-molybdenum steel trellis frame for rigidity and strength. 💡 Technology Features Infotainment Infotainment System: N/A (purpose-built off-road competition machines) Driver Assistance Driver Assistance Features: N/A (mechanical simplicity prioritized for off-road performance) Connectivity Connectivity Features: N/A Ignition System Ignition Type: Digital CDI ignition with variable ignition timing. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to the specific owner's manual, but typically every 15-25 hours of riding for aggressive use. Air Filter Cleaning: Frequent cleaning/replacement recommended, often after every few rides depending on conditions. Valve Adjustment Interval: Typically every 50-100 hours of riding, depending on use. Fluid Specifications Engine Oil Type: KTM recommends...