This manual is for following models. years 2000-2005
KTM 250EXC Racing
KTM 400EXC Racing
KTM 450SX, EXC, MXC Racing
KTM 525SX, EXC, MXC Racing
This manual contains 4 separate manuals. This is the factory manual, one file. Pages 410. Index ribbon is active and searchable.
1 Engine repair manual(index listed)
1 SERVICE-INFORMATIONS
2 GENERAL INFORMATION
3 REMOVING AND REFITTING ENGINE
4 DISASSEMBLING ENGINE
5 SERVICING INDIVIDUAL COMPONENTS
6 ASSEMBLING ENGINE
7 ELECTRICAL
8 FUEL SYSTEM
9 TROUBLE SHOOTING
10 TECHNICAL SPECIFICATIONS
11 PERIODIC MAINTENANCE SCHEDULE
12 WIRING DIAGRAMS
2 Owners manual which covers chassis and electrical
The owner manual provides essential information with regard to the operation and maintenance of this bike.
Careful handling, correct periodical inspections, adjustments and maintenance.
3 Fork rebuild manual
Introduction 2
Exploded view 3
Disassembly forkleg 4
Disassembly cartridge 17
Disassembly compression holder 21
Assembling compression holder 24
Disassembly tap rebound 27
Assembling tap rebound 31
Assembling cartridge 34
Assembling forkleg 37
4 Shock rebuild manual
Introduction 2
Exploded view 3
Disassembly shock absorber 4
Disassembly tube side 13
Disassembly MCC 33
Assembling MCC 39
Assembling Tube side 44
Disassembly piston-rod side 53
Disassembly adaptor DU-bush 63
Assembling adaptor DU-bush 67
Assembling piston-rod side 70
Assembling shock absorber 81
Bleeding 87
On pressure with nitrogen 92
Mounting spring 95
Adjustment 98