KTM 250 400 450 525 SX-EXC Complete Workshop Service Repair Manual 2000 2001 2002 2003 2004 2005 2006 2007

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Typ: Motorcycle

Anbieter:

Art.-Nr: 93082

Stichworte: 2000 2001 2002 2003 2004 2005 2006 2007 250 EXC 250 SX 400 EXC 400 SX 450 EXC 450 SX 525 EXC 525 SX KTM Misc Motorcycle Motorcycles

Produktvarianten

Beschreibung

This manual covers the SX-EXC Series motorcycles, including 2-stroke and 4-stroke variants from model years 2000 through 2007. These high-performance off-road motorcycles are renowned for their powerful engines, advanced chassis design, and exceptional handling capabilities, making them a dominant force in motocross and enduro racing. Available in displacements such as 250cc, 400cc, 450cc, and 525cc, the SX models are purpose-built for motocross competition, while the EXC variants are designed for the rigors of enduro riding. The reputation for engineering quality, reliability, and a strong racing pedigree are key differentiators for these machines. This comprehensive workshop service and repair manual provides essential technical knowledge for maintaining, diagnosing, and repairing your SX-EXC Series motorcycle. It details procedures for all major systems, including the engine, transmission, chassis, and electrical components, covering everything from routine maintenance and scheduled checks to complete component overhauls and rebuilds. With step-by-step instructions, torque specifications, and diagnostic guides, this manual is an indispensable resource for owners, mechanics, and technicians seeking to keep these high-performance off-road bikes in optimal condition.

🏷️ Basic Information

Identification

Make:

Model:

SX-EXC Series (2-stroke and 4-stroke variants)

Covered Years:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Engine Displacements Covered:

250cc, 400cc, 450cc, 525cc

Model Variants Covered:

SX (Motocross), EXC (Enduro)

Codes

Engine Codes:

Varies by specific model and year (e.g., LC4 for larger displacements)

👋 Introduction

Market Position

Segment:

High-performance off-road motorcycles (Motocross and Enduro)

Target User:

Enthusiast owners, amateur and professional racers, independent repair shops, KTM service centers.

Competitive Analysis

Competitors:

Yamaha YZ/WR series, Honda CR/CRF series, Suzuki RM/DRZ series, Kawasaki KX/KLX series.

Key Differentiators:

KTM's reputation for powerful engines (especially the LC4 lineage), advanced chassis design, and racing pedigree.

Key Features

Manual Value:

Provides the essential technical knowledge to maintain, diagnose, and repair these high-performance machines effectively, saving time and money on professional servicing.

Vehicle Appeal:

Known for their aggressive styling, potent engines, and exceptional handling capabilities in their respective classes.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Workshop Service and Repair

Geographic Relevance:

Global (with specific regional differences noted where applicable for parts/fluids)

Page Count

Estimated Page Count:

High (Likely 500+ pages, comprehensive coverage)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital File (likely PDF)

📖 Manual Coverage

Systems Covered

Engine:

Top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (liquid-cooled variants), fuel system (carburetor/injection), ignition system, exhaust system

Transmission:

Clutch, gearbox (gear selection, ratios), final drive (chain and sprockets)

Chassis:

Frame inspection and repair, suspension (forks, rear shock absorber, linkage), steering system, wheels, hubs, spokes, braking system (hydraulic front and rear), controls (levers, cables)

Electrical:

Wiring diagrams, lighting system, ignition system, battery, charging system (alternator/stator), starter system (electric start variants), instrumentation, sensors

Bodywork:

Body panels, seat, fuel tank, fenders, graphics, ergonomics

Procedures Included

Maintenance:

Scheduled maintenance checks, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment (if applicable), brake pad replacement, fluid flushes

Troubleshooting:

Diagnostic procedures for common issues, fault finding, symptom-based troubleshooting guides

Repair:

Component disassembly, inspection, repair, and reassembly for all major systems. Engine rebuild procedures, transmission overhaul, suspension servicing, brake caliper rebuild.

Installation:

Instructions for installation of common aftermarket or OEM replacement parts.

Technical Depth

Depth:

Comprehensive. Covers basic adjustments to full engine and transmission rebuilds. Includes torque specifications, clearances, and detailed step-by-step instructions with diagrams.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Resolution:

High-resolution scans or original digital source, ensuring clarity of text and diagrams.

Binding Type

Physical Binding:

N/A (Digital format)

Paper Type

Physical Paper:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Type:

Four-stroke, single-cylinder, liquid-cooled (common for EXC variants and later SX models in this range); some early models or specific variants might be two-stroke.

Bore X Stroke:

Varies significantly by displacement (e.g., 450 SX-F would differ from 250 SX-F).

Valve Train:

DOHC, 4 valves (typical for 4-stroke models)

Performance

Horsepower:

Generous power output for displacement, typically ranging from 45-60+ HP depending on model and tuning.

Torque:

Strong mid-range and top-end torque delivery, characteristic of KTM off-road engines.

Fuel System

Carburetor Spec:

Keihin flat-slide carburetors (e.g., PWK series) common in early models; Mikuni also used.

Fuel Injection Spec:

Keihin or Delphi electronic fuel injection (EFI) introduced on some later models within this range.

Cooling System

Type:

Pressurized liquid cooling system with electric fan on some models.

🔧 Transmission

Standard

Type:

Constant mesh, sequential 5 or 6-speed gearbox.

Optional

Configurations:

N/A (Standardized for model type)

Features

Clutch Type:

Hydraulic multi-plate wet clutch.

Final Drive:

O-ring sealed chain drive.

📐 Dimensions

Exterior

Seat Height:

High, typical for off-road competition bikes (e.g., 37-39 inches).

Ground Clearance:

Generous, designed for off-road obstacles.

Weights

Dry Weight:

Generally lightweight, aiming for optimal power-to-weight ratio (e.g., 220-250 lbs).

Fuel Tank Capacity:

Typically around 2-3 gallons.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not subject to standardized crash test ratings like cars).

Active Features

Braking System:

High-performance hydraulic disc brakes front and rear, often with Brembo components.

Suspension Handling:

Advanced suspension systems (WP Suspension) contribute to stability and control.

Passive Features

Chassis Design:

Chromoly steel frame provides strength and rider feedback.

💡 Technology Features

Infotainment

Features:

Basic digital instrumentation (speedometer, odometer, trip meter, engine hour meter, warning lights). No advanced infotainment systems.

Driver Assistance

Features:

N/A (Focus is on rider control and mechanical feedback).

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-20 hours of riding for competition use, or as specified in the manual. Owner's manual might suggest longer for casual use.

Air Filter Cleaning:

Frequent cleaning required, often before or after every ride depending on conditions.

Spark Plug Replacement:

As per manual recommendations, typically based on hours or specific mileage.

Fluid Specifications

Engine Oil:

High-quality synthetic motorcycle oil, typically 10W-40 or 10W-50, meeting specific JASO standards (e.g., MA/MA2).

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 4 or DOT 5.1 high-temperature hydraulic brake fluid.

Clutch Fluid:

Typically Mineral Oil (for Magura hydraulic clutches common on KTMs) or DOT 4 brake fluid depending on the specific master cylinder.

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve stem seals, wheel bearings, steering head bearings, swingarm bearings, fork seals.

Potential Problems:

Overheating on older models with undersized radiators, occasional carburetor jetting issues, cam chain tensioner wear on some 4-stroke engines.

Maintenance Tips

Pre Ride Checks:

Tire pressure, chain tension, fluid levels, brake operation, bolt tightness.

📚 Vehicle History

Brand Heritage

Origin:

Austrian manufacturer with a strong legacy in off-road and racing disciplines.

Racing Success:

Extensive history of victories in Motocross Grand Prix, Enduro World Championships, and Dakar Rally.

Model Evolution

Development Focus:

Continuous refinement of engine performance, suspension, chassis dynamics, and weight reduction.

Technology Adoption:

Transition from carbureted to fuel-injected engines, updates in suspension technology, and frame design advancements within this generation.

Production

Manufacturing Location:

Primarily Austria, with potential for some components or assembly in other regions.

Key Production Years:

The manual covers a specific, well-defined generation of these models, representing a significant era of KTM's off-road development.

🏆 Awards & Recognition

Recognitions

Motocross Titles:

KTM SX models have numerous national and international motocross championships across various classes.

Enduro Titles:

KTM EXC models are highly decorated in enduro racing, including multiple ISDE wins and world championships.

Ratings

Editorial Reviews:

Consistently receive high praise from motorcycle publications for performance, handling, and durability in demanding off-road conditions.

Certifications

Emission Standards:

Compliant with relevant emission standards for their model years and intended markets (may vary).