This manual covers a comprehensive range of off-road motorcycles, including the 250 SX, 400 SX, 450 SX, 520 SX, 525 SX, 250 MXC, 400 MXC, 450 MXC, 525 MXC, 250 EXC, 400 EXC, 450 EXC, and 525 EXC models manufactured between 2000 and 2003. Known for their Austrian engineering, the SX, MXC, and EXC lines are celebrated for their performance-oriented design, powerful engines, and proven success in competitive off-road racing, making them a top choice for riders seeking capability and durability in demanding conditions. This service and repair manual provides detailed instructions and technical specifications essential for the maintenance and repair of your motorcycle. It encompasses all critical systems, including engine disassembly and assembly, transmission service, brake system maintenance, electrical system troubleshooting, suspension adjustments, and chassis work. The manual is designed to empower owners and technicians with the knowledge required for routine servicing, complex repairs, and performance tuning, ensuring the longevity and optimal operation of these high-performance off-road machines. 🏷️ Basic Information Identification Make: KTM Model: 250 SX, 400 SX, 450 SX, 520 SX, 525 SX, 250 MXC, 400 MXC, 450 MXC, 525 MXC, 250 EXC, 400 EXC, 450 EXC, 525 EXC Product Name: KTM 250 400 450 520 525 SX MXC EXC 2000-2003 All Service Repair Manual Download Generation Model Years Covered: 2000, 2001, 2002, 2003 👋 Introduction Market Position Target Audience: KTM motorcycle owners, DIY enthusiasts, independent repair shops. Competitive Analysis Value Proposition: Empowers owners to perform repairs and maintenance themselves, saving money and ensuring quality. Key Features Accessibility: Instant download for immediate access to repair information. Comprehensiveness: Covers a wide range of models and all essential repair and maintenance aspects. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for KTM SX, MXC, and EXC models Page Count Estimated Page Count: Varies by specific model and engine variant, typically between 300-600 pages for a complete set. Manual Type Type: Service Repair Manual, Workshop Manual, Troubleshooting Guide Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Service Repair: Complete disassembly, assembly, tuning, and overhaul of all engine variants. Transmission Service Repair: Detailed procedures for clutch, gearbox, and final drive maintenance and repair. Brake System: Service and repair of hydraulic brake systems, including caliper, master cylinder, and fluid maintenance. Wiring Diagram: Comprehensive electrical wiring diagrams for all electrical components and systems. Electrical System: Troubleshooting and repair of ignition, lighting, charging, and other electrical circuits. Suspension: Fork and shock absorber service, tuning, and adjustments for front and rear suspension. Steering: Maintenance and repair of the steering head bearings and linkage. Cooling System: Service and maintenance of the liquid cooling system, including radiators and water pump. Fuel System: Maintenance and repair of carburetors (relevant models) and fuel delivery systems. Chassis Body: Frame inspection, bodywork repair, seat, and fuel tank servicing. Wheels And Tires: Information on wheel bearing service, spoke tensioning, and tire pressure recommendations. Procedures Included General Maintenance: Routine checks, cleaning, lubrication, and adjustments. Troubleshooting: Diagnostic procedures for common and uncommon issues, with symptom-based solutions. Periodic Lubrication: Detailed lubrication schedules and specifications for all moving parts. Restraint System: Not applicable for the primary models covered, as these are off-road motorcycles without traditional restraint systems. Engine Rebuild: Step-by-step instructions for complete engine teardown and rebuild, including torque specifications. Carburetor Tuning: Detailed guidance on adjusting and rebuilding carburetors for optimal performance. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and chassis overhauls. 📊 Manual Specifications File Format Format: PDF Software Requirements: Adobe PDF Reader, WinZip (or similar unzipping software) Compatibility: Compatible with all versions of Windows and Mac OS Print Quality Quality: High-resolution digital images and text for clear reproduction. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder (details vary by specific model: 250cc, 400cc, 450cc, 520cc, 525cc). Cooling: Liquid-cooled Ignition: Electronic ignition system (details vary by model). Performance Horsepower: Varies by displacement, generally in the range of 30-60 HP (approximate). Torque: Varies by displacement, generally in the range of 25-50 lb-ft (approximate). Fuel System Fuel Delivery: Carburetor (e.g., Keihin FCR for most models in this era). Fuel Type: Unleaded gasoline (Octane rating specified in manual). 🔧 Transmission Standard Type: 5-speed or 6-speed constant mesh gearbox (specific to model variant). Optional Options: N/A for these specific factory models, modifications are aftermarket. Features Clutch: Hydraulically operated multi-plate wet clutch. Final Drive: Chain drive. 📐 Dimensions Exterior Frame Type: Chromium-molybdenum steel perimeter frame (typical for KTM). Weights Dry Weight: Varies significantly by model and engine size, typically between 230-260 lbs (approximate). 🛡️ Safety Features Ratings Crash Test Results: N/A (Off-road motorcycles are not subjected to standard automotive crash testing). Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Handlebar Design: Fat bar handlebars for improved control and impact absorption....