Engine Variants:
250, 400, 450, 525
Production Years Covered By Manual:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Chassis Code General:
Likely to vary by model and year, common for SX/EXC/MXC series
Engine Code General:
LC4-based variants for 400, 450, 525; RFS engine for 250 and some 400/450 models
Category:
High-performance off-road motorcycles (Enduro and Motocross variants).
Target Audience:
Enthusiast owners, amateur and professional racers, service technicians.
Competitors:
Honda CRF series, Yamaha YZ/WR series, Suzuki RM/DRZ series, Kawasaki KX/KLX series, Husqvarna TE/TC series, Beta RR series.
Performance Focus:
Emphasis on powerful engines and capable off-road chassis for competitive use.
Manual Benefit:
Enables owners and technicians to maintain and repair these complex machines effectively, maximizing performance and longevity.
Delivery Method:
Instant digital delivery via PDF download on payment day.
Shipping Policy:
1-day shipping, file within 12 hours.
Models Covered:
KTM 250 EXC Racing, 400 EXC Racing, 450 SX, 450 MXC, 450 EXC Racing, 525 SX, 525 MXC, 525 EXC Racing
Year Coverage Clarification:
Explicitly states 2000-2007, noting commonality of components through 2005.
Estimated Page Count:
Likely 500-800+ pages, typical for comprehensive service manuals of this era.
Type:
Service Repair Manual / Workshop Manual
Language:
English (Presumed, standard for this market)
Format:
PDF Download (Ebook)
Engine:
Complete overhaul, diagnostics, tuning, performance adjustments, specific sub-assemblies (e.g., cylinder head, piston, crankshaft, camshafts, valve train), lubrication system, cooling system.
Transmission:
Gearbox disassembly and reassembly, clutch operation and adjustment, shift mechanism, internal components.
Fuel System:
Carburetor (Keihin CVK/FCR) servicing, jetting, fuel pump (if applicable to specific models/years), fuel tank, fuel lines, filters.
Ignition System:
CDI unit, ignition coil, spark plug, timing, troubleshooting.
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, switches, fuses.
Suspension:
Front fork (USD WP components) disassembly, servicing, oil changes, seal replacement, damping adjustments, rear shock absorber service and adjustment.
Brakes:
Hydraulic brake systems (front and rear calipers, master cylinders, brake lines, brake pads), bleeding procedures, rotor inspection.
Chassis And Frame:
Frame inspection, sub-frame, steering head bearings, swingarm, linkage systems (if applicable), wheel bearings.
Bodywork And Plastics:
Fairing removal and installation, seat, fuel tank cover, fenders, graphics.
Cooling System:
Radiator service, hoses, coolant specifications, fan operation (if equipped).
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, spark plug checks, bolt torque checks, valve clearance checks.
Troubleshooting:
Diagnostic flowcharts, common problem identification and solutions for engine, electrical, and mechanical issues.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component rebuilds, complete brake system servicing.
Component Disassembly And Reassembly:
Detailed step-by-step instructions for virtually all mechanical components.
Specifications And Torques:
Comprehensive list of all critical torque values, clearances, fluid capacities, and specifications.
Depth:
Comprehensive, covering everything from basic rider maintenance to full workshop-level engine and chassis overhauls. Includes detailed diagrams and exploded views.
Searchability:
Likely text-searchable PDF, enhancing ease of finding information.
Printability:
Printable, allowing users to create hard copies of specific sections or the entire manual.
Quality:
Digital PDF quality, ensuring clarity of text and diagrams.
Type:
N/A (Digital PDF, not a printed manual)
Type:
N/A (Digital PDF, not a printed manual)
Engine Type:
Single-cylinder, 4-stroke. Specific engine families include the RFS (Ready For السعر) for smaller displacements and LC4-based engines for larger displacements, though many 400-525 models in this range are RFS variants.
Bore X Stroke 250:
Approximately 76 x 54.8 mm (RFS 250)
Bore X Stroke 400:
Approximately 84.5 x 72 mm (RFS 400/450, can vary slightly)
Bore X Stroke 450:
Approximately 95 x 63.4 mm (RFS 450/525)
Bore X Stroke 525:
Approximately 97 x 70.8 mm (RFS 525/530)
Valve Train:
SOHC (Single Overhead Camshaft) with 4 valves, operated by rocker arms.
Cooling System:
Liquid-cooled, with radiator and fan (on some models).
Horsepower 250:
Estimated 40-45 HP at peak (stock)
Horsepower 400:
Estimated 45-50 HP at peak (stock)
Horsepower 450:
Estimated 50-55 HP at peak (stock)
Horsepower 525:
Estimated 55-60 HP at peak (stock)
Torque Peak:
Varies significantly with displacement, generally strong low-to-mid range torque characteristic of KTM off-road engines.
Carburetor Type:
Keihin CVK or FCR (Flat Slide Carburetor) depending on specific model and year. FCR is generally considered higher performance.
Fuel Type:
Unleaded gasoline, typically 91-95 RON (Octane rating may vary by region).
Fuel Delivery:
Gravity feed from fuel tank to carburetor.
General Type:
Compact, purpose-built off-road motorcycle design.
Seat Height:
High seat height typical for off-road performance, often around 37-38 inches (940-965 mm).
Ground Clearance:
Significant ground clearance, typically 13-15 inches (330-380 mm).
Dry Weight:
Approx. 105-115 kg (231-253 lbs), depending on model and displacement.
Wet Weight:
Likely around 115-125 kg (253-275 lbs) with all fluids.
Oil Change Engine:
Typically every 15-20 hours of riding, or annually. Manual will provide exact recommendation.
Air Filter Cleaning:
Recommended every 5-10 hours of riding, or after each event in dusty conditions.
Valve Clearance Check:
Typically every 30-40 hours of riding.
Spark Plug Replacement:
Inspect every 20 hours, replace as needed. Manual will specify type and gap.
Engine Oil:
KTM recommends specific motorcycle-specific 4-stroke oils, often with an ester base. Viscosity typically 10W-40 or 10W-50. Manual will specify exact KTM part number or SAE grade. Motorex is a common supplier.
Coolant:
Ethylene glycol-based antifreeze mixture with distilled water. Manual will specify the ratio and potentially a specific coolant type (e.g., Motorex Coolant).
Brake Fluid:
DOT 4 brake fluid (also used for clutch hydraulic system).
Fork Oil:
Specific WP fork oil viscosity (e.g., WP Suspension Fluid 0W, 2.5W, 5W). Manual will specify type and fill volume.
Gearbox Oil:
Separate gearbox oil, typically 10W-40 or 80W gear oil. Manual will specify the exact type and capacity. Often same as engine oil for simplicity in some older models, but separate for RFS.
Common Wear Items:
Piston rings, valve seats, wheel bearings, steering head bearings, swingarm bearings, clutch plates.
Carburetor Cleaning:
Regular cleaning and adjustment of the Keihin carburetors is crucial for optimal performance.
Radiator Fan Failure:
On models equipped with electric fans, wiring or fan motor failure can occur.
Water Pump Seal:
Water pump seal leaks can occur with age and mileage.
Cam Chain Tensioner:
Early RFS models sometimes had issues with cam chain tensioners; manual may cover replacement procedures or updates.
Origin:
KTM AG, an Austrian manufacturer renowned for its off-road racing heritage and success.
Lineage:
These models represent a significant period of KTM's dominance in off-road racing, particularly with the RFS engine platform, known for its reliability and performance. Successors would see further evolution in engine technology (fuel injection) and chassis design.
Manufacturing Location:
Austria (Primary manufacturing)
Peak Era Significance:
These years are considered a golden age for KTM's off-road competition bikes, with numerous championship wins across various disciplines.
