KTM 250 400 450 520 525 SX MXC EXC 2000-2003 Service Manual

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This manual covers SX, MXC, and EXC models from the 2000, 2001, 2002, and 2003 model years, featuring single-cylinder, four-stroke engines with displacements ranging from 250cc to 525cc. The brand...

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Typ: Motorcycle

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Art.-Nr: 58126

Stichworte: 2000 2001 2002 2003 250 EXC 250 MXC 250 SX 400 EXC 400 MXC 400 SX 450 EXC 450 MXC 450 SX 520 EXC 520 MXC 520 SX 525 EXC 525 MXC 525 SX ATV KTM Motorcycle Powersports

Produktvarianten

Beschreibung

This manual covers SX, MXC, and EXC models from the 2000, 2001, 2002, and 2003 model years, featuring single-cylinder, four-stroke engines with displacements ranging from 250cc to 525cc. The brand is renowned for its high-performance off-road motorcycles, and these models represent a significant period of development in their four-stroke technology, offering competitive chassis and potent engine performance. These versatile machines are engineered for motocross, cross-country, and enduro riding, built with the quality and durability expected from the brand's racing heritage. This comprehensive Service Repair Workshop Manual provides factory-level information in English for owners and mechanics. It details routine maintenance, periodic checks, lubrication, and step-by-step repair instructions for all major systems, including the engine, fuel, cooling, transmission, electrical, suspension, and bodywork. With detailed specifications, troubleshooting guidance, and clear illustrations and wiring schematics, this manual is an essential resource for maintaining and repairing your motorcycle, enabling efficient servicing and informed decision-making.

🏷️ Basic Information

Identification

Make:

Model:

SX, MXC, EXC

Applicable Model Years:

2000, 2001, 2002, 2003

Engine Variants Covered:

250cc, 400cc, 450cc, 520cc, 525cc

Codes

Manual Code:

Not specified (vehicle specific)

👋 Introduction

Market Position

Target Audience:

KTM owners, independent mechanics, service professionals

Value Proposition:

Enables cost savings on maintenance and repairs, empowers informed decision-making.

Competitive Analysis

Uniqueness:

Vehicle-specific, factory-level information, not generic.

Key Features

Content Features:

Step-by-step instructions, diagrams, illustrations, wiring schematics, specifications, troubleshooting.

Benefit 1:

Facilitates easy and safe servicing and repair for users with basic mechanical knowledge.

Benefit 2:

Reduces reliance on expensive dealership service.

Accessibility:

Viewable on PC, Mac, phones, and e-readers; printable pages.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop

Scope:

Comprehensive for mechanics and owners

Page Count

Estimated Page Count:

Large (exact number not provided, but described as 'full' and 'complete')

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine Specifications, Engine Removal and Installation, Intake & Exhaust

Fuel System:

Fuel System

Cooling System:

Cooling System

Transmission Drivetrain:

Transmission, Drive Chain, Sprockets

Electrical System:

Electrical System, Wiring Diagram

Suspension Steering:

Steering System, Shocks

Bodywork:

Body Work

Procedures Included

Maintenance:

Routine Maintenance, Periodic Checks and Adjustments, Lubrication

Repair:

Step-by-step repair instructions for all covered systems

Diagnostics:

Advanced Troubleshooting

Troubleshooting:

Integrated troubleshooting guidance

Technical Depth

Depth:

Comprehensive, detailed, factory-level information

Diagrams:

Diagrams, Illustrations

Wiring Schematics:

Detailed Wiring Schematics

📊 Manual Specifications

File Format

Format:

Compatibility:

All Versions of Windows and Mac

Requirements:

Adobe PDF Reader

Print Quality

Printability:

Yes, all pages printable

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Types:

Single-cylinder, four-stroke engines

Displacements Covered:

250cc, 400cc, 450cc, 520cc, 525cc

Performance

Horsepower Range:

Varies by model and displacement (specific figures not in description, but covered in manual)

Torque Range:

Varies by model and displacement (specific figures not in description, but covered in manual)

Fuel System

Fuel Delivery:

Carburetor (typical for this era, specific details in manual)

Engine Specifications Coverage

Coverage:

Detailed engine specifications provided in the manual.

🔧 Transmission

Standard

Transmission Type:

Likely 6-speed manual (typical for SX/MXC/EXC models of this era)

Optional

Optional Transmissions:

Not applicable for these off-road models

Features

Gear Ratios:

Specific gear ratios for each model and variant are detailed in the manual.

Clutch Type:

Hydraulic wet multi-plate clutch (typical for KTM off-road)

📐 Dimensions

Exterior

Body Style:

Dirt Bike / Motocross / Enduro

Weights

Dry Weight:

Varies by model and displacement (specific figures covered in manual)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable for off-road motorcycles in the same way as cars.

Active Features

Active Safety:

Focus on rider skill and vehicle control; manual covers braking system maintenance.

Passive Features

Passive Safety:

Frame integrity, suspension damping, rider protection equipment (not covered in manual itself).

💡 Technology Features

Infotainment

Infotainment Systems:

Not applicable to these models, which are focused on performance and off-road capability.

Driver Assistance

Driver Assistance Features:

Not applicable.

Connectivity

Connectivity Features:

Not applicable.

Electrical System

Lighting:

Basic lighting systems (headlight, taillight) for trail riding, detailed in electrical section.

🔧 Maintenance

Service Intervals

Routine Maintenance:

Covered extensively, including oil changes, filter cleaning/replacement, chain adjustment, spark plug checks.

Periodic Checks:

Detailed schedules for checks and adjustments are provided.

Fluid Specifications

Engine Oil:

Specific oil viscosity grades and API specifications (e.g., SAE 10W-50, JASO MA) are detailed in the manual.

Coolant:

Recommended coolant type and mixture ratio (e.g., ethylene glycol-based) are specified.

Brake Fluid:

DOT 4 or DOT 5.1 brake fluid typically recommended (specifics in manual).

Gear Oil:

Specific gear oil specifications and capacities are provided.

Known Issues

Common Wear Items:

Piston rings, valve guides, clutch plates, chain and sprockets are typical wear items for high-performance off-road motorcycles of this era. Manual provides inspection and replacement procedures.

Carburetor Tuning:

Carburetor jetting and adjustment are critical for optimal performance at different altitudes and temperatures, covered in the manual.

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM is renowned for its off-road motorcycles, particularly in motocross, enduro, and rally racing.

Model Evolution

Model Lineage:

SX (Motocross), MXC (Cross-Country), EXC (Enduro) are established KTM model lines with long histories of development and racing success.

Era Significance:

The 2000-2003 period represents a significant era of development for KTM's four-stroke off-road machines, with continuous improvements in engine performance, chassis, and suspension.

Production

Manufacturing Location:

Austria (KTM's primary manufacturing base)

🏆 Awards & Recognition

Recognitions

Brand Recognition:

KTM consistently receives accolades for performance and durability in off-road racing and championships.

Ratings

Performance Ratings:

Models from this era were highly regarded for their powerful engines and competitive chassis in their respective classes.

Certifications

Certification:

Manual itself is not certified, but it provides the manufacturer's official service procedures.