This manual covers SX and EXC series motorcycles produced between 2000 and 2007. These high-performance off-road machines, available in approximately 250cc, 400cc, 450cc, and 525cc displacements, are renowned for their potent LC4 engine platform, liquid-cooled operation, and robust chromium-molybdenum steel trellis frames. The SX models are designed for motocross racing, while the EXC variants are built for enduro competition, both benefiting from extensive racing heritage and reputation for off-road prowess. This comprehensive workshop service repair manual in English provides detailed, step-by-step instructions for maintenance, troubleshooting, and repair across all major vehicle systems. Coverage includes engine, transmission, fuel, ignition, electrical, suspension, chassis, brakes, and wheels. It offers crucial technical data, specifications, torque values, fluid requirements, and diagnostic procedures, empowering owners and technicians to maintain and restore these motorcycles effectively and efficiently, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: 250 SX, 400 SX, 450 SX, 525 SX, 250 EXC, 400 EXC, 450 EXC, 525 EXC Codes Model Code Range: SX series (Motocross), EXC series (Enduro) 👋 Introduction Market Position Target Audience: Owners, mechanics, and enthusiasts of KTM SX and EXC models from 2000-2007 for maintenance, repair, and restoration. Competitive Analysis Value Proposition: Provides essential technical data and repair procedures necessary for maintaining and servicing these high-performance off-road motorcycles, saving significant costs compared to professional dealer service. Key Features Content Focus: Detailed step-by-step instructions, exploded views, diagrams, torque values, and diagnostic charts. 📋 Manual Details Coverage Areas Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Page Count Estimated Page Count: Comprehensive (typical workshop manual for this era and range of models is 400-600+ pages, actual may vary based on specific printing/digitalization). Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, overhaul, top end (cylinder, piston, valves), bottom end (crankshaft, connecting rod, bearings), cooling system (radiator, fan, coolant), lubrication system (oil pump, oil filter, oil passages). Transmission Drivetrain: Gearbox inspection, disassembly, assembly, shift mechanism, clutch (hydraulic or cable), primary drive, chain drive, sprockets. Fuel System: Carburetor (jetting, float bowl, needle, idle speed), fuel pump (if applicable for later models or specific variants), fuel tank, fuel lines, filters. Ignition Electrical: Ignition system (CDI, stator, coil), lighting system (if applicable to EXC models), battery, wiring diagrams, starter motor, troubleshooting electrical faults. Suspension Chassis: Front suspension (forks - disassembly, seals, oil level, valving, spring replacement), rear suspension (shock absorber - rebuild, damping adjustments, linkage system), swingarm, bearings. Brakes: Front and rear brake systems (calipers, master cylinders, brake lines, pads, rotors), bleeding procedure, hydraulic system troubleshooting. Wheels Tires: Wheel bearing inspection and replacement, spoke tension, tire mounting, rim maintenance. Bodywork Frame: Frame inspection, seat, fuel tank removal/installation, plastics, handlebars, controls. Procedures Included Maintenance Tasks: Routine maintenance checks, oil changes, filter replacements, spark plug service, chain adjustment, air filter cleaning/replacement, valve clearance checks. Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting guides, electrical fault finding. Repair Procedures: Detailed step-by-step instructions for component disassembly, repair, and reassembly for all major systems. Technical Data Specs: Torque specifications for all fasteners, fluid capacities, engine timing, electrical resistance values, dimensional data. Technical Depth Depth Of Coverage: Comprehensive rebuilds, advanced diagnostics, detailed component overhauls, troubleshooting of complex issues. 📊 Manual Specifications File Format File Format: PDF Print Quality Resolution: High-resolution scans (typically 300 dpi or higher for clarity). Searchability: Likely text-searchable PDF if OCR was performed, otherwise image-based. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder (LC4 engine family for most, though specific iterations vary) Displacement Options: Approximately 250cc, 400cc, 450cc, 525cc (exact CC may vary slightly by year and specific sub-model). Cooling System: Liquid-cooled Performance Horsepower Range: Varies by displacement; e.g., 250s typically 30-40 HP, 525s 45-55+ HP (peak figures). Torque Range: Varies by displacement; e.g., 250s 20-25 lb-ft, 525s 35-45+ lb-ft. Fuel System Fuel Delivery: Carbureted (e.g., Keihin, Mikuni models depending on year/variant) Recommended Fuel: Unleaded gasoline, octane rating as specified by KTM (typically 91 RON or higher). 🔧 Transmission Standard Transmission Type: 6-speed manual gearbox Features Clutch Type: Hydraulic actuated wet multi-plate clutch Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Varies by model, typically around 1470-1500 mm (57.9-59.1 inches). Weights Dry Weight: Varies by model and year, generally between 105-120 kg (231-265 lbs). 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Off-road motorcycles are not subject to standard automotive crash testing. Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Frame Construction: Chromium-molybdenum steel trellis frame. 💡 Technology Features Infotainment Features: Basic motorcycle instrumentation (speedometer, tachometer, odometer, hour meter). No advanced infotainment systems. Driver Assistance Features: None (Focus is on pure off-road performance). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-15 hours of...