🏷️ Basic Information Identification Make: KTM Model: SX / EXC / MXC Engine Variants: 250, 400, 450, 525 Production Years Covered By Manual: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Code General: Likely to vary by model and year, common for SX/EXC/MXC series Engine Code General: LC4-based variants for 400, 450, 525; RFS engine for 250 and some 400/450 models 👋 Introduction Market Position Category: High-performance off-road motorcycles (Enduro and Motocross variants). Target Audience: Enthusiast owners, amateur and professional racers, service technicians. Competitive Analysis Competitors: Honda CRF series, Yamaha YZ/WR series, Suzuki RM/DRZ series, Kawasaki KX/KLX series, Husqvarna TE/TC series, Beta RR series. Key Features Performance Focus: Emphasis on powerful engines and capable off-road chassis for competitive use. Manual Benefit: Enables owners and technicians to maintain and repair these complex machines effectively, maximizing performance and longevity. Delivery Method: Instant digital delivery via PDF download on payment day. Shipping Policy: 1-day shipping, file within 12 hours. 📋 Manual Details Coverage Areas Models Covered: KTM 250 EXC Racing, 400 EXC Racing, 450 SX, 450 MXC, 450 EXC Racing, 525 SX, 525 MXC, 525 EXC Racing Year Coverage Clarification: Explicitly states 2000-2007, noting commonality of components through 2005. Page Count Estimated Page Count: Likely 500-800+ pages, typical for comprehensive service manuals of this era. Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English (Presumed, standard for this market) Format Format: PDF Download (Ebook) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, tuning, performance adjustments, specific sub-assemblies (e.g., cylinder head, piston, crankshaft, camshafts, valve train), lubrication system, cooling system. Transmission: Gearbox disassembly and reassembly, clutch operation and adjustment, shift mechanism, internal components. Fuel System: Carburetor (Keihin CVK/FCR) servicing, jetting, fuel pump (if applicable to specific models/years), fuel tank, fuel lines, filters. Ignition System: CDI unit, ignition coil, spark plug, timing, troubleshooting. Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, switches, fuses. Suspension: Front fork (USD WP components) disassembly, servicing, oil changes, seal replacement, damping adjustments, rear shock absorber service and adjustment. Brakes: Hydraulic brake systems (front and rear calipers, master cylinders, brake lines, brake pads), bleeding procedures, rotor inspection. Chassis And Frame: Frame inspection, sub-frame, steering head bearings, swingarm, linkage systems (if applicable), wheel bearings. Bodywork And Plastics: Fairing removal and installation, seat, fuel tank cover, fenders, graphics. Cooling System: Radiator service, hoses, coolant specifications, fan operation (if equipped). Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, spark plug checks, bolt torque checks, valve clearance checks. Troubleshooting: Diagnostic flowcharts, common problem identification and solutions for engine, electrical, and mechanical issues. Major Repairs: Engine rebuilds, transmission overhauls, suspension component rebuilds, complete brake system servicing. Component Disassembly And Reassembly: Detailed step-by-step instructions for virtually all mechanical components. Specifications And Torques: Comprehensive list of all critical torque values, clearances, fluid capacities, and specifications. Technical Depth Depth: Comprehensive, covering everything from basic rider maintenance to full workshop-level engine and chassis overhauls. Includes detailed diagrams and exploded views. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF, enhancing ease of finding information. Printability: Printable, allowing users to create hard copies of specific sections or the entire manual. Print Quality Quality: Digital PDF quality, ensuring clarity of text and diagrams. Binding Type Type: N/A (Digital PDF, not a printed manual) Paper Type Type: N/A (Digital PDF, not a printed manual) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke. Specific engine families include the RFS (Ready For السعر) for smaller displacements and LC4-based engines for larger displacements, though many 400-525 models in this range are RFS variants. Bore X Stroke 250: Approximately 76 x 54.8 mm (RFS 250) Bore X Stroke 400: Approximately 84.5 x 72 mm (RFS 400/450, can vary slightly) Bore X Stroke 450: Approximately 95 x 63.4 mm (RFS 450/525) Bore X Stroke 525: Approximately 97 x 70.8 mm (RFS 525/530) Valve Train: SOHC (Single Overhead Camshaft) with 4 valves, operated by rocker arms. Cooling System: Liquid-cooled, with radiator and fan (on some models). Performance Horsepower 250: Estimated 40-45 HP at peak (stock) Horsepower 400: Estimated 45-50 HP at peak (stock) Horsepower 450: Estimated 50-55 HP at peak (stock) Horsepower 525: Estimated 55-60 HP at peak (stock) Torque Peak: Varies significantly with displacement, generally strong low-to-mid range torque characteristic of KTM off-road engines. Fuel System Carburetor Type: Keihin CVK or FCR (Flat Slide Carburetor) depending on specific model and year. FCR is generally considered higher performance. Fuel Type: Unleaded gasoline, typically 91-95 RON (Octane rating may vary by region). Fuel Delivery: Gravity feed from fuel tank to carburetor. 🔧 Transmission Standard Type: 6-speed constant mesh manual transmission. Optional Type: N/A (Standard for this performance category) Features Clutch Type: Hydraulically operated, multi-plate wet clutch. Gear Ratios: Specific ratios vary by model (SX vs. EXC) and engine size. Manual...