🏷️ Basic Information

Make:

KTM

Model:

SX, MXC, EXC, EGS, EXC Racing

Model Variants:

250, 400, 450, 520, 525

Years Covered:

2000, 2001, 2002, 2003

Generation Identifier:

LC4 4-Stroke Era (Early)

👋 Introduction

Target Audience:

DIY enthusiasts, home mechanics, and professional technicians working on KTM off-road motorcycles.

Value Proposition:

Provides essential technical information and repair procedures for a range of popular KTM models, enabling cost-effective maintenance and repair.

Manual Benefits:

High-quality diagrams, comprehensive coverage, instant download for immediate access, cost savings on postage and packaging.

Diagram Quality:

Contains high-quality diagrams essential for understanding complex assemblies and procedures.

📋 Manual Details

Coverage Scope:

Comprehensive service and repair for 2000-2003 KTM 4-stroke off-road models.

Estimated Page Count:

Varies by specific model and engine size, but generally extensive for a workshop manual.

Manual Classification:

Workshop Service Repair Manual

Primary Language:

English

Text Searchability:

PDF format typically allows for text searching of keywords.

Digital Format:

PDF

Compatibility:

Compatible with all versions of Windows & Mac.

📖 Manual Coverage

Engine Systems:

Engine removal and refitting, disassembly, component servicing, assembly, troubleshooting.

Electrical Systems:

Wiring diagrams, troubleshooting electrical issues.

Chassis Systems:

Frame inspection, suspension (front forks, rear shock absorber) service and adjustment, wheel bearing maintenance.

Fuel System Components:

Carburetor removal, cleaning, adjustment, and troubleshooting.

Cooling System:

Radiator and hose inspection, coolant replacement, troubleshooting overheating.

Maintenance Procedures:

Periodic maintenance schedule, fluid changes, filter replacements, general servicing.

Repair Procedures:

Detailed step-by-step instructions for engine and component repair.

Torque Specifications:

Crucial torque values for critical fasteners throughout the engine and chassis are provided.

Troubleshooting Flowcharts:

Likely includes structured troubleshooting guides for common starting, running, and performance issues.

Diagnostic Capabilities:

Troubleshooting guides for common issues, technical specifications for accurate diagnosis.

Rebuild Depth:

Complete engine disassembly and reassembly procedures suitable for full rebuilds.

📊 Manual Specifications

File Type:

PDF

Software Requirement:

Adobe PDF Reader.

Printability:

All pages are printable.

Binding Method:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

4-Stroke, Liquid-Cooled Single Cylinder (LC4 engine family)

Displacement Range:

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

Bore Stroke Variations:

Specific bore and stroke dimensions vary significantly across the 250, 400, 450, 520, and 525cc displacements.

Fuel Delivery System:

Primarily Carbureted (Mikuni or Keihin, specific model dependent), potential for early fuel injection on some late models/variants, though unlikely for this specific year range in this context.

Valve Train:

SOHC or DOHC (depending on specific engine variant within the LC4 family, though SOHC is more prevalent for earlier models in this range).

Cooling System:

Liquid-cooled via radiator and fan (electric fan on some models/years).

🔧 Transmission

Transmission Type:

5-speed or 6-speed manual gearbox (specific to model and year).

Clutch Type:

Wet, multi-plate clutch (hydraulic actuation common).

Drive System:

Chain drive (rear wheel).

Gear Ratios:

Gear ratios are specific to each model and engine size and would be detailed within the manual.

📐 Dimensions

Chassis Type:

Chromium-molybdenum steel trellis frame.

Suspension Type Front:

Upside-down (USD) telescopic forks (e.g., WP).

Suspension Type Rear:

Monoshock with linkage (e.g., WP).

Dry Weight Range:

Approximately 105-120 kg (231-265 lbs), varies significantly by model and engine size.

🛡️ Safety Features

Safety Standards:

N/A (Off-road competition motorcycles, typically not subjected to DOT/NHTSA safety ratings).

Braking System:

Hydraulic disc brakes front and rear (Brembo calipers common).

Frame Integrity:

Robust steel trellis frame designed for off-road stress.

💡 Technology Features

Display System:

Basic LCD display showing trip meter, odometer, clock, and neutral indicator. No advanced infotainment.

ABS Availability:

ABS was not a standard or commonly available option on these off-road competition models of this era.

Connectivity Features:

N/A. Focus is on mechanical and electrical systems for performance.

🔧 Maintenance

Oil Change Interval:

Typically every 10-15 hours of riding or annually, consult manual for specific model recommendations.

Air Filter Cleaning:

Frequent cleaning/replacement is critical for off-road performance, often every few rides.

Engine Oil Grade:

Recommended API SG or higher, SAE 10W/40 or 15W/50 motorcycle-specific oil (e.g., Motorex Power Synt).

Coolant Type:

Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Motorex Coolant M3.0).

Transmission Oil Grade:

Separate transmission oil, typically SAE 75W/80 or 85W gear oil, or motorcycle-specific 4-stroke gearbox oil.

Common Wear Items:

Clutch plates, valve stem seals, cam chain tensioner, carburetor jets (depending on usage).

Electrical Gremlins:

Wire chafing in harness, faulty grounds, especially around the headlight/handlebar area.

Carburetor Maintenance:

Carburetors require regular cleaning and adjustment due to dirt ingress in off-road environments.

📚 Vehicle History

Brand Focus:

KTM has a strong heritage in off-road racing (Motocross, Enduro, Rally) and is known for its 'Ready to Race' philosophy.

Lc4 Significance:

The LC4 engine platform was a dominant force in KTM's off-road lineup during this period, known for its torque and durability.

Racing Variant Focus:

The SX (Motocross), MXC (Cross Country), and EXC (Enduro) designations highlight the distinct performance characteristics and intended uses of these models.

Manufacturing Location:

Austria (KTM AG).

🏆 Awards & Recognition

Racing Heritage:

KTM models of this era achieved significant success in various off-road racing disciplines, underscoring their performance and durability.