🏷️ Basic Information Identification Make: KTM Model: SX / MXC / EXC Engine Variants: 250cc, 400cc, 450cc, 520cc, 525cc Generation Production Years: 2000, 2001, 2002, 2003 👋 Introduction Market Position Target Audience: Professional technicians, experienced DIY enthusiasts, and owners seeking in-depth maintenance and repair knowledge. Competitive Analysis Comparison To Paper: Offers the same depth of information as a factory service manual or paper manual, with the added benefit of instant access and digital searchability. Key Features Content Focus: Step-by-step repair procedures, critical specifications, illustrations/pictures, maintenance schedules, disassembly/assembly guides, cleaning instructions, and reinstallation procedures. 📋 Manual Details Coverage Areas Coverage: Comprehensive repair and service for KTM 250 SX, 400 SX, 450 SX, 520 SX, 525 SX, 250 MXC, 400 MXC, 450 MXC, 520 MXC, 525 MXC, 250 EXC, 400 EXC, 450 EXC, 520 EXC, 525 EXC models. Page Count Page Count: Not Specified (Digital PDF format, content driven) Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end rebuild, piston and cylinder service, valve adjustment, crankshaft and connecting rod service, oil pump operation, cooling system. Transmission Drivetrain: Gearbox disassembly and assembly, clutch service, chain and sprocket maintenance, final drive. Chassis Suspension: Front fork service (WP Suspension), rear shock absorber service, linkage maintenance, steering head bearing service, wheel bearing replacement. Electrical Systems: Wiring diagrams, ignition system troubleshooting, lighting system, battery and charging system, starter system. Fuel System: Carburetor tuning and overhaul, fuel tank inspection, fuel line maintenance. Braking System: Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, hydraulic system bleeding. Bodywork Frame: Frame inspection, body panel removal and installation, seat, fenders, exhaust system. Procedures Included Maintenance Procedures: Routine maintenance checks, oil and filter changes, air filter cleaning, chain lubrication and adjustment, brake fluid checks. Repair Procedures: Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly. Troubleshooting: Diagnostic charts and guidance for identifying and resolving common problems. Technical Depth Depth: Suitable for professional technicians and advanced DIY mechanics with basic electrical and mechanical knowledge. Covers detailed rebuild procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Printable: Full Printable Zoom Capability Zoom: Zoom IN/OUT enabled Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility Operating Systems: All Versions of Windows & Mac Binding Type Binding Type: Digital Download (not applicable for physical binding) Paper Type Paper Type: Digital PDF (printable on user's choice of paper) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke single-cylinder (typically LC4 engine for larger displacements, 2-stroke for 250SX). Performance Horsepower Torque: Varies significantly by displacement (e.g., approx. 30-40 HP for 250cc, 50+ HP for 525cc). Specific figures require consulting the manual or model-specific data. Fuel System Carburetor Type: Mikuni VM or Keihin carburetor common for these models. Specific sizes vary by engine displacement and model year. Cooling System Cooling Method: Liquid-cooled (radiator and fan for most models in this range). 🔧 Transmission Standard Transmission Type: Constant-mesh, 5 or 6-speed manual transmission. Features Clutch Type: Hydraulically operated multi-plate wet clutch. 📐 Dimensions Exterior Frame Type: Chromium-molybdenum steel, perimeter frame. Weights Dry Weight: Typically in the range of 100-120 kg (220-265 lbs) depending on engine size and model variant. Specific weights vary. 🛡️ Safety Features Ratings Safety Features Notes: As off-road motorcycles, standard automotive safety ratings do not apply. Emphasis is on rider safety through component integrity and maintenance. Active Features Braking System Type: Hydraulic disc brakes front and rear. Brembo components often utilized. 💡 Technology Features Infotainment Infotainment Features: Not applicable to these off-road models; focus is on performance and functionality. Driver Assistance Electronic Aids: Generally limited to basic ignition and lighting systems. No modern electronic rider aids like ABS or traction control. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 15-30 engine hours or annually, depending on usage. Specific recommendation within manual. Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours). Fluid Specifications Engine Oil Type: High-quality motorcycle-specific 4-stroke engine oil, e.g., SAE 10W-40 or 10W-50, meeting JASO MA standards. Specific grade found in manual. Coolant Type: Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water. Brake Fluid Type: DOT 4 or DOT 5.1 hydraulic brake fluid. Known Issues Common Wear Items: Clutch plates, valve guide wear (especially on high-mileage LC4 engines), wheel bearings, fork seals, swingarm bearings, kickstand switch failures. Carburetor Tuning: Can be sensitive to altitude and temperature changes, requiring periodic adjustment. 📚 Vehicle History Brand Heritage Brand Focus: KTM is renowned for its off-road racing heritage, particularly in motocross (SX), enduro (EXC), and rally raids. Model Evolution Lc4 Engine: The LC4 engine platform, used in larger displacements (400-525cc) during this period, was a cornerstone of KTM's adventure and dual-sport line-up, with performance-oriented off-road variants like the SX and EXC. Production Manufacturing Location: Primarily...