Engine Variants Covered:
250cc, 400cc, 450cc, 520cc, 525cc
Model Generation:
Likely represents the 2000 model year updates and variants of the SX, MXC, and EXC platforms.
Vehicle Type:
Off-road Motorcycle
Target Audience:
KTM owners and independent motorcycle mechanics seeking to perform comprehensive maintenance and repairs.
Value Proposition:
Provides essential technical information for maintaining and repairing a range of high-performance KTM off-road motorcycles, enabling cost savings and greater self-sufficiency.
Downloadable Format:
Instant access and convenient storage on digital devices.
Comprehensiveness:
Covers a wide array of maintenance, repair, and diagnostic procedures across multiple engine displacements and model lines.
Primary Coverage:
Comprehensive service and repair for KTM 250, 400, 450, 520, and 525 SX, MXC, and EXC models.
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, and technical specifications.
Estimated Page Count:
Varies by specific model and engine variant, typically between 300-500 pages for a comprehensive manual.
Type:
Service and Repair Manual
Engine:
Complete disassembly, assembly, inspection, repair, and overhaul procedures for all listed engine displacements (250cc, 400cc, 450cc, 520cc, 525cc).
Transmission:
Service and repair of gearbox, clutch, and shifting mechanisms.
Brakes:
Front and rear brake system maintenance, repair, and bleeding procedures (hydraulic systems).
Electrical:
Wiring diagrams, ignition system, lighting, charging system (stator/rotor), and component troubleshooting.
Suspension:
Front fork (USD - Upright/Inverted Dual) and rear shock absorber service, tuning, and seal replacement.
Fuel System:
Carburetor (likely Keihin or Mikuni) service, adjustment, and jetting; fuel tank and petcock maintenance.
Cooling System:
Radiator, hoses, and coolant maintenance and inspection (liquid-cooled variants).
Chassis Bodywork:
Frame inspection, body panel removal/installation, seat, and general chassis components.
Steering:
Handlebar, triple clamps, and steering head bearing service.
Wheels Tires:
Wheel bearing maintenance, tire inspection, and wheel removal/installation.
Maintenance:
Routine checks, cleaning, lubrication, adjustments, and replacement of wear items.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems.
Repair:
Step-by-step instructions for component repair and replacement.
Rebuild:
Complete engine and major component rebuild procedures.
Diagnostics:
Fault finding and diagnostic techniques for electrical and mechanical systems.
Diagnostic Level:
Advanced diagnostics and troubleshooting, suitable for experienced mechanics and ambitious DIYers.
Repair Detail:
Detailed disassembly, assembly, and adjustment procedures with torque specifications and clearances.
Maintenance Schedule:
Periodic maintenance schedules including oil changes, filter replacements, valve clearance checks, and lubrication points.
Engine Type:
Four-stroke single-cylinder (typical for this era of EXC/MXC, SX may have variants).
Bore X Stroke:
Varies by displacement: e.g., 250cc might be ~76mm x 54.8mm, 525cc might be ~95mm x 72mm. Precise figures are within the manual.
Valve Train:
DOHC (Double Overhead Camshaft), 4 valves per cylinder (typical).
Horsepower Range:
Approx. 25-55 HP depending on displacement and tuning.
Torque Range:
Varies significantly by displacement, detailed specifications within the manual.
Carburetor Type:
Likely Keihin FCR or similar constant-velocity carburetor (specific model dependent).
Ignition System:
Digital CDI (Capacitor Discharge Ignition).
Oil Change Interval:
Typically every 15-20 operating hours or annually, depending on usage severity.
Air Filter Cleaning:
Every few riding days or as needed based on dust conditions.
Valve Clearance Check:
Every 40-50 operating hours or annually.
Engine Oil:
Specific viscosity grade (e.g., 10W-40 or 10W-50) and API classification as per manual. Often specific motorcycle-grade oils.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Coolant:
Ethylene glycol-based antifreeze coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Common Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, fork seals, and chain/sprockets.
Potential Failures:
Carburetor jetting sensitivity, occasional stator issues, and worn swingarm/linkage bearings.
Ktm Focus:
KTM has a strong heritage in off-road racing and performance motorcycles, known for their 'Ready to Race' philosophy.
Sx Mxc Exc Lineage:
These lines represent KTM's competitive offerings in motocross (SX), cross-country (MXC), and enduro (EXC) disciplines, evolving significantly year-over-year.
Manufacturing Location:
Austria (KTM AG's primary manufacturing base).
