Model:
Multiple (EXC, SX, MXC, XC, XC-W, EXC, SMR, SXS, CRATE)
Engine Platform:
Shared Engine Architecture
Production Years:
2000-2007
Engine Codes Indicated:
LC4, LC4-E (specific designations may vary by model and year)
Target Audience:
DIY owners, independent mechanics, workshops, enthusiasts seeking detailed repair and maintenance information.
Competitor Manuals:
OEM service manuals, Haynes, Clymer (though often less detailed than OEM).
Manual Advantage:
Comprehensive coverage across multiple engine displacements and model variants within a specific generation, detailed illustrations, direct application to professional technician procedures.
Value Proposition:
Cost savings through self-maintenance and repair, empowerment of owners with technical knowledge.
Digital Accessibility:
Instant download, accessible on multiple devices (computer, tablet, etc.), no physical storage limitations.
Covered Model Years:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Covered Motorcycle Models:
KTM 250 EXC, KTM 400 SX, KTM 400 MXC, KTM 400 XC, KTM 400 XC-W, KTM 400 EXC, KTM 400 SMR, KTM 400 SXS, KTM 450 SX, KTM 450 MXC, KTM 450 XC, KTM 450 XC-W, KTM 450 EXC, KTM 450 SMR, KTM 450 SXS, KTM 520 SX, KTM 520 MXC, KTM 520 XC, KTM 520 XC-W, KTM 520 EXC, KTM 520 SMR, KTM 525 SX, KTM 525 MXC, KTM 525 XC, KTM 525 XC-W, KTM 525 EXC, KTM 525 SMR, KTM 540 SMR, KTM 610 CRATE
Estimated Page Count:
Varies (up to 3000 MB suggests a very comprehensive manual, likely several hundred pages if printed)
Manual Type:
Service Repair Manual / Workshop Manual / Factory Manual
Delivery Format:
Digital Download (PDF, ZIP, RAR, EXE)
Engine Systems:
Engine disassembly, assembly, repair, troubleshooting, component servicing, internal lubrication, cooling system, fuel system, ignition system, exhaust system, engine management.
Transmission Systems:
Gearbox disassembly, assembly, repair, clutch operation and service, gear shift mechanism.
Electrical Systems:
Wiring diagrams, ignition system components, lighting, starter system, charging system, electronic control units (ECUs), sensor diagnostics.
Chassis Systems:
Suspension (forks, rear shock), braking system (hydraulic circuits, components), steering, wheels and tires.
Bodywork And Frame:
Frame inspection, fairings, seat, fuel tank mounting and servicing.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug service, valve clearance adjustment, chain adjustment, brake fluid replacement, coolant replacement.
Repair Procedures:
Complete engine rebuild, gearbox overhaul, suspension fork service, brake caliper rebuild, carburetor overhaul, electrical component testing and replacement.
Troubleshooting Guidance:
Systematic diagnosis of common problems, symptom-based troubleshooting charts, error code interpretation (if applicable).
Diagnostic Procedures:
Checking component functionality, electrical system testing, pressure testing (e.g., fuel pressure).
Depth Of Coverage:
Comprehensive (from basic maintenance to complete engine and component overhauls, including detailed exploded views).
Diagnostic Capabilities:
Advanced diagnostics for engine performance and electrical systems.
Rebuild Instructions:
Detailed step-by-step instructions for engine and major component rebuilds.
File Type:
PDF (commonly), ZIP, RAR, EXE
Searchability:
Likely text-searchable PDF, depending on origin and scanning quality.
Printable:
Yes, can be printed on any printer.
Illustration Quality:
Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views.
Binding:
Not Applicable (Digital Download)
Paper Type:
Not Applicable (Digital Download)
Maximum File Size:
Up to 3000 MB
Engine Type:
Four-stroke, single-cylinder (primarily LC4 architecture)
Engine Displacements Covered:
250cc, 400cc, 450cc, 520cc, 525cc, 540cc, 610cc
Horsepower Range:
Varies significantly by displacement and specific model tune (e.g., 30-55+ HP)
Torque Range:
Varies significantly by displacement and specific model tune (e.g., 30-50+ lb-ft)
Fuel Delivery Systems:
Carburetor (Mikuni VM/TM, Keihin FCR) or Fuel Injection (EFI on later models within the range, though less common for these specific displacements in this period).
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual)
Ignition Type:
CDI (Capacitor Discharge Ignition) or Electronic Ignition
Cooling Method:
Liquid-cooled (radiator, fan)
Lubrication System:
Wet Sump (with integrated oil cooler for some models)
Transmission Type:
5-speed or 6-speed sequential manual gearbox
Optional Transmissions:
Not applicable for this generation of off-road/motocross bikes.
Clutch Type:
Wet multi-plate clutch (Hydraulic actuation)
Gear Ratios:
Specific gear ratios detailed within the manual for each model variant.
Transmission Oil Type:
KTM recommends specific motorcycle-specific transmission oil or high-quality ester-based 10W/40 or 10W/50 synthetic oil. Refer to manual for precise specifications and brands.
Typical Wheelbase:
Approximately 1460-1500 mm (varies by model)
Typical Seat Height:
Approximately 950-990 mm (varies by model)
Typical Dry Weight:
Approximately 110-130 kg (varies by model and engine size)
Typical Wet Weight:
Approximately 125-145 kg (varies by model and engine size)
Safety Ratings:
Not applicable for off-road motorcycles in a crash-test rating context.
Braking System:
Hydraulic disc brakes, front and rear (Brembo calipers common).
Suspension Damping:
Adjustable front forks (compression, rebound) and rear shock absorber (preload, compression, rebound) for optimizing handling and stability.
Lighting System:
Headlight, taillight, brake light, turn signals (depending on model legality/trim).
Oil Change Interval:
Typically every 10-15 hours of riding for competitive off-road use, or annually. Refer to manual for specific recommendations based on usage.
Air Filter Cleaning:
Frequent cleaning/replacement recommended, especially in dusty conditions. Often every 5-10 hours.
Valve Clearance Check:
Typically every 20-40 hours of riding. Manual provides specific tolerance values.
Engine Oil Capacity:
Varies by model and displacement (e.g., 1.5 - 2.0 liters). Refer to manual.
Coolant Type:
Ethylene glycol-based antifreeze mixture with distilled water. Specific ratios detailed in manual.
Brake Fluid Type:
DOT 4 hydraulic brake fluid is standard. Always use fresh fluid.
Common Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings, fork seals, swingarm bearings.
Potential Failures:
Carburetor jetting issues, fuel pump problems (on FI models), starter motor issues, radiator leaks, kickstart mechanism wear (on older models).
Importance Of Cleaning:
Thorough cleaning after each ride is crucial for identifying leaks, damage, and maintaining overall condition.
Brand Focus:
KTM is renowned for its 'Ready to Race' philosophy, excelling in off-road motorsports like Motocross, Enduro, and Dakar Rally.
Lc4 Engine Legacy:
The LC4 engine platform has a long and successful history for KTM, known for its robust nature and strong torque output, evolving through various displacements and refinements.
Manufacturing Location:
Austria (primarily)
Motorsport Success:
KTM motorcycles of this era achieved numerous victories and championships in Enduro, Cross-Country, and Motocross racing, validating their performance and durability.
Independent Reviews:
Generally praised for power, handling, and off-road capability, with common critiques relating to vibration and maintenance requirements typical of high-performance singles.
Manufacturing Standards:
Adherence to ISO standards for manufacturing and quality control.
