🏷️ Basic Information Identification Make: KTM Model: SX / EXC Covered Years: 2000-2006 Engine Displacements Covered: 250cc, 400cc, 450cc, 520cc, 525cc Codes Manual Product Name: Ktm 250 400 450 520 525 Sx Exc 2000 2006 Service Manual PDF Download 👋 Introduction Market Position Category: High-performance off-road motorcycles (Motocross and Enduro) Competitive Analysis Competitors: Yamaha YZ/WR series, Honda CR/CRF series, Suzuki RM/RMX series, Kawasaki KX/KDX series Key Features Performance Focus: Known for powerful engines, lightweight chassis, and aggressive styling. Off Road Capability: Designed for extreme off-road conditions, sand, mud, and rough terrain. Value Proposition Manual Benefit: Essential for DIY maintenance and repair, saving significant costs compared to professional service. 📋 Manual Details Coverage Areas General Coverage: Complete vehicle from start to finish Specific Coverage List: General Information, Routine Maintenance, Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Transmission, Drive Chain & Sprockets, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting Page Count Estimated Page Count: Exact page count not provided, but described as an 'absolute wealth of information'. Manual Type Type: Factory Service Workshop Repair Manual Language Language: English Format File Format: PDF Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader Printability: All pages are printable Access: Instant PDF download, providing immediate access to repair information. 📖 Manual Coverage Systems Covered Engine Systems: Engine Removal/Installation, Fuel System, Lubrication & Cooling, Engine Specifications, Intake & Exhaust Drivetrain Systems: Transmission, Drive Chain & Sprockets Chassis Systems: Steering System, Shocks, Body Work Electrical Systems: Electrical System Suspension Details: Front forks (e.g., WP USD forks) and rear shock absorber specifications, adjustments, and service procedures. Frame And Subframe: Inspection, maintenance, and repair of the frame, swingarm, and subframe. Procedures Included Maintenance Procedures: Routine Maintenance, Recommended Service Intervals (implied) Repair Procedures: Engine Repair, Transmission Repair, Steering System Repair, Suspension (Shocks) Repair, Body Work Repair, Electrical System Troubleshooting and Repair Diagnostic Procedures: Advanced Troubleshooting Troubleshooting Methodology: Systematic approach to diagnosing common and complex issues, including electrical gremlins and engine performance problems. Engine Rebuild: Comprehensive instructions for engine disassembly, inspection, component replacement, and reassembly for full rebuilds. Technical Depth Depth: Professional mechanic level, covering comprehensive servicing and repair. 📊 Manual Specifications File Format Format: PDF Searchability: PDF format typically allows for text search, enhancing usability. Print Quality Quality: High-quality digital reproduction, suitable for printing. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format, printable on user-selected paper) ⚙️ Engine Specifications Primary Engine Engine Type General: Single-cylinder, 4-stroke engines. Engine Configurations: 250cc, 400cc, 450cc, 520cc, 525cc variants Performance Power Delivery: Emphasis on strong mid-range and top-end power for competition. Cooling System: Liquid-cooled (typical for these models) Fuel System Carburetor Type: Likely Keihin (common for KTM during this era), specific model/size will be in manual. Engine Components Valve Train: DOHC (Dual Overhead Camshaft) Piston Design: Manual will detail piston types (e.g., forged), ring specifications, and piston-to-cylinder clearance. Lubrication Oil System: Dedicated oil sump with oil filter (details provided in manual). 🔧 Transmission Standard Type: 5-speed manual transmission. Features Gear Ratios: Specific gear ratios for each engine displacement are detailed in the manual. Clutch Type: Hydraulically actuated wet multi-plate clutch (typical for KTM). Maintenance Fluid Type: Manual will specify appropriate transmission oil/ATF. Typically SAE 10W/10W-40, or specific KTM-recommended fluids. Drivetrain Final Drive: O-ring sealed drive chain and sprockets. 📐 Dimensions Weights Dry Weight Estimate: Varies by model/displacement, typically in the range of 230-250 lbs (approx. 104-113 kg) for 4-stroke SX/EXC models of this era. Exact figures will be in the manual. 🛡️ Safety Features Ratings Safety Standard: Off-road competition vehicles, not typically rated by consumer safety organizations like NHTSA or Euro NCAP. Active Features Braking System: Hydraulic disc brakes (front and rear). Manual covers brake caliper, master cylinder, fluid, and pad maintenance/replacement. Passive Features Frame Construction: Chromoly steel frame (typical for KTM). 💡 Technology Features Infotainment Features: N/A (Performance off-road motorcycles, typically minimal rider electronics beyond basic instrumentation). Driver Assistance Features: N/A Engine Management Ignition System: Digital CDI (Capacitor Discharge Ignition), manual covers ignition timing, spark plug specifications, and troubleshooting. 🔧 Maintenance Service Intervals Routine Maintenance: Manual provides detailed schedules for tasks like oil changes, filter cleaning/replacement, chain adjustment, valve checks, spark plug replacement, etc., specific to operating hours or mileage. Fluid Specifications Engine Oil Type: Manual will specify KTM-recommended oil grades (e.g., SAE 10W-50, 10W-40, or specific formulations for wet clutches). Coolant Type: Manual will specify the type of coolant (e.g., ethylene glycol-based antifreeze with corrosion inhibitors). Brake Fluid Type: DOT 4 brake fluid (typical). Fork Oil Type: Manual will specify the type and viscosity of fork oil, and oil level for suspension service. Known Issues Common Wear Items: Manual will cover inspection and replacement of wear items such as piston rings, valve guides, clutch plates, wheel bearings, fork seals, and swingarm bushings. Preventative Maintenance...