🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Racing Model Variants: 250, 400, 520, 525 Year Range: 2000, 2001, 2002, 2003, 2004 Codes Manual Code Prefix: Likely starts with '8000...' 👋 Introduction Market Position Segment: High-performance off-road motorcycles (Motocross, Enduro, Supercross) Target Audience: Professional racers, serious amateur riders, mechanics, and KTM enthusiasts. Competitive Analysis Competitors: Yamaha YZ, Honda CRF/CR, Suzuki RM/RM-Z, Kawasaki KX/KX-F. Unique Selling Points: KTM's reputation for powerful engines, advanced WP suspension, and robust build quality for demanding off-road use. Key Features Manual Benefit: Provides essential information for maintaining peak performance and longevity of these competitive machines. Manual Accuracy: OEM equivalent ensures factory-correct procedures and specifications. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Rebuilds Page Count Estimated Pages: Likely 300-600 pages (typical for comprehensive service manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive engine disassembly, inspection, assembly, tuning, and repair for all listed displacements. Cooling System: Radiator, coolant flow, fan operation, thermostat, and related components. Fuel System: Carburetor(s) (Mikuni VM series likely), fuel pump, fuel lines, fuel tank inspection and cleaning. Ignition System: CDI unit, spark plug, ignition coil, wiring, timing specifications. Transmission: Clutch operation, gearbox disassembly, inspection, assembly, gear selection, and lubrication. Suspension: Front forks (WP USD likely) - disassembly, seal replacement, oil levels and types, damping adjustments. Rear shock absorber - servicing, spring preload, damping adjustments. Brakes: Hydraulic brake systems (front and rear), caliper service, pad replacement, fluid type (DOT 4 likely), bleeding procedures. Electrical System: Wiring diagrams, battery maintenance, lighting, starter motor, charging system, fuses, switches. Chassis: Frame inspection, steering head bearing service, wheel bearing replacement, spoke tensioning. Bodywork: Fairing removal and installation, seat, fuel tank cover, fenders. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, valve clearance adjustments. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides. Engine Repair: Top-end rebuilds (piston, rings, cylinder), bottom-end rebuilds (crankshaft, bearings), timing chain replacement. Transmission Repair: Gearbox disassembly and reassembly, clutch plate replacement. Suspension Servicing: Fork seal replacement, fork oil change, rear shock absorber rebuild. Brake System Maintenance: Brake bleeding, caliper piston service, fluid replacement. Electrical Diagnostics: Wiring harness troubleshooting, component testing. Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Diagnostic Level: Includes detailed diagnostic flowcharts and component testing procedures. Rebuild Level: Covers complete engine and transmission rebuilds, including specifications and torque values. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing quick access to information. Print Quality Image Resolution: Expect clear diagrams and high-resolution images suitable for printing. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, four-stroke (typically SOHC or DOHC depending on specific model year and variant). Displacement 250: 250cc (Approximate) Displacement 400: 400cc (Approximate) Displacement 520: 520cc (Approximate) Displacement 525: 525cc (Approximate) Cooling: Liquid-cooled Starting System: Kick-start (likely primary, some models might have electric start option but less common for this era SX/MXC). Performance Horsepower 250: Estimated 35-45 HP (Varies by model and tuning) Horsepower 525: Estimated 50-60 HP (Varies by model and tuning) Torque Curve: Broad and torquey, characteristic of KTM's off-road focused engines. Fuel System Carburetor Type: Mikuni VM Series (e.g., VM38 or VM40 likely for larger displacements). Fuel Type: Unleaded gasoline (Octane rating specified in manual, typically 91+). Fluid Specifications Engine Oil Type: High-quality motorcycle-specific 4-stroke engine oil (e.g., Motorex or equivalent, SAE 10W/40 or 15W/50 depending on temperature). Engine Oil Capacity: Approximately 0.8 - 1.2 liters (refer to manual for exact capacity by model). Coolant Type: Ethylene glycol-based coolant (50/50 mix with distilled water recommended). 🔧 Transmission Standard Type: Constant mesh, sequential manual gearbox. Number Of Gears: Typically 5 or 6 speeds (manual will specify for each model variant). Optional Optional Features: N/A (These were performance-oriented, typically no automatic options). Features Clutch Type: Wet multi-plate clutch, hydraulically operated. Transmission Oil Type: Often shared with engine oil (JASO MA rated) or separate transmission oil specified. 📐 Dimensions Exterior Wheelbase: Varies by model, but typically around 57-58 inches (1450-1475 mm). Seat Height: High seat height typical of off-road bikes, around 37-39 inches (940-990 mm). Weights Dry Weight: Approx. 230-255 lbs (105-115 kg) depending on engine size and model variant. 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycles are not typically subjected to standardized crash testing like cars). Active Features Braking System: Powerful hydraulic disc brakes front and rear for superior stopping power. Passive Features Frame Construction: Chromoly steel trellis frame providing strength and rigidity for off-road abuse. 💡 Technology Features Infotainment Infotainment Features: N/A (These are competition motorcycles designed for performance, not comfort or entertainment features). Driver Assistance Assistance Features: N/A (No electronic rider aids like ABS or traction control...