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

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Mots clés: 2000 2001 2002 2003 250 EXC 250 MXC 250 SX 400 EXC 400 MXC 400 SX 450 EXC 450 MXC 450 SX 520 520 SX 525 EXC 525 MXC 525 SX KTM Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the SX, MXC, and EXC models manufactured between 2000 and 2003, featuring engine variants of 250cc, 400cc, 450cc, 520cc, and 525cc. These high-performance off-road motorcycles are renowned for their racing heritage and 'Ready to Race' philosophy, offering robust engineering and powerful performance characteristic of a commitment to off-road excellence. The models utilize four-stroke, single-cylinder engines, typically liquid-cooled, and are equipped with 5-speed manual transaxles and hydraulically actuated multi-plate wet clutches, providing a direct and responsive riding experience. This comprehensive workshop service repair manual provides detailed information for the maintenance, diagnosis, and repair of your motorcycle. It includes step-by-step instructions for engine mechanical and electrical systems, fuel systems, transmission, clutch, brakes, suspension, steering, and bodywork. The manual also covers scheduled maintenance, fluid specifications, troubleshooting guides, and wiring diagrams, making it an essential resource for both DIY enthusiasts and professional mechanics seeking to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Model:

SX, MXC, EXC

Engine Variants:

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

Production Years:

2000, 2001, 2002, 2003

👋 Introduction

Market Position

Segment:

High-performance off-road motorcycles (Motocross, Enduro, Dual-Sport).

Competitive Analysis

Competitors:

Yamaha YZ/WR series, Honda CR/CRF series, Suzuki RM/RM-Z series, Kawasaki KX/KDX series.

Key Features

Manual Features:

Detailed illustrations, diagrams, wiring schematics, step-by-step instructions, troubleshooting guides, and specifications.

Value Proposition

Cost Savings:

Inexpensive way to maintain and repair vehicles, avoiding costly dealership labor.

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive service and repair for KTM 250, 400, 450, 520, and 525 SX, MXC, and EXC models from 2000-2003.

Page Count

Estimated Page Count:

Varies by specific model and engine size; typically 300-600+ pages for complete workshop manuals.

Manual Type

Type:

Workshop Service Repair Manual / Factory Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed repair, overhaul, and component replacement procedures for all engine variants.

Engine Electrical:

Diagnosis, troubleshooting, and repair of the electrical system, including ignition and charging.

Emission Control:

Information related to emission control systems, if applicable to the target market/model year.

Fuel System:

Carburetor inspection, adjustment, and overhaul; fuel pump and line service.

Suspension:

Front fork and rear shock absorber service, seal replacement, and damping adjustments.

Clutch:

Clutch assembly inspection, adjustment, and replacement procedures.

Transmission:

Manual transaxle system repair, maintenance, and troubleshooting.

Drivetrain:

Driveshaft and axle inspection and service.

Steering:

Steering system maintenance and component replacement.

Brakes:

Hydraulic brake system inspection, bleeding, pad replacement, and caliper service.

Body Interior Exterior:

Fairing, seat, and other bodywork component service.

Body Electrical:

Wiring diagrams and troubleshooting for auxiliary electrical systems.

Restraints:

Information on seat belts and other restraint systems, if applicable.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, lubrication, and general upkeep.

Troubleshooting:

Diagnostic guides for identifying and resolving common and uncommon problems.

Repair:

Step-by-step instructions for component disassembly, repair, reassembly, and adjustment.

Diagnostics:

Detailed diagnostic procedures for all major systems.

Wiring Diagrams:

Comprehensive wiring schematics for electrical system troubleshooting and repair.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and chassis rebuilds.

Target Audience:

Suitable for both DIY enthusiasts and professional mechanics.

📊 Manual Specifications

File Format

File Type:

Software Requirements:

Adobe Acrobat Reader

Print Quality

Printability:

Fully printable

Zoom Capability:

YES (Zoom IN/OUT enabled)

Binding Type

Binding:

Digital (PDF download)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder (typical for this era of KTM off-road).

Displacement Options:

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

Performance

Horsepower Torque:

Specific figures vary significantly by displacement; manual provides detailed specifications for each model.

Fuel System

Carburetion:

Mikuni or Keihin carburetors common for this period.

Cooling System

Cooling Method:

Liquid-cooled (typical for performance KTMs of this era).

🔧 Transmission

Standard

Type:

5-speed manual transaxle (standard for SX, MXC, EXC).

Optional

Optional Types:

N/A (Manual transmission standard).

Features

Gear Ratios:

Specific gear ratios detailed within the manual for each model variant.

Clutch Type:

Hydraulically actuated multi-plate wet clutch.

📐 Dimensions

Exterior

General Dimensions:

Dimensions vary by model; manual provides detailed specs for each.

Weights

Dry Weight:

Varies by model and displacement (e.g., approximate dry weight range from ~230-250 lbs).

Wet Weight:

Varies by model and fluid capacities.

🛡️ Safety Features

Ratings

Safety Certifications:

Off-road motorcycles typically not rated by NHTSA; compliance with local regulations is expected.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Passive Features

Frame Construction:

Chromium-molybdenum steel trellis frame.

💡 Technology Features

Infotainment

Display Systems:

Basic digital or analog instrument clusters showing speed, RPM, and basic warning lights.

Driver Assistance

Electronic Aids:

Primarily mechanical systems; no advanced electronic rider aids like ABS or traction control on these models.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 hours of riding, or as specified in the manual.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions; intervals as per manual.

Valve Adjustment Interval:

Varies by model, typically every 20-40 hours of riding.

Fluid Specifications

Engine Oil Type:

Refer to manual for specific grade and API classification (e.g., Motorex or equivalent SAE 10W/40 or 15W/50 semi-synthetic or fully synthetic motorcycle oil).

Coolant Type:

Ethylene glycol-based antifreeze/coolant mixture.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals, swingarm bearings, cam chains (depending on specific engine design).

Potential Failures:

KTMs from this era are generally robust, but meticulous maintenance is key. Refer to the manual's troubleshooting section for specific model year concerns.

📚 Vehicle History

Brand Heritage

Ktm Heritage:

KTM has a long history in off-road racing, known for its 'Ready to Race' philosophy.

Model Evolution

Development Period:

The 2000-2003 models represent a significant period in KTM's development of their four-stroke off-road platforms, particularly the LC4 engine family.

Production

Manufacturing Location:

Austria (primary manufacturing)

🏆 Awards & Recognition

Recognitions

Racing Success:

KTM models of this era achieved significant success in various off-road racing disciplines (Motocross, Enduro, Dakar Rally).

Ratings

Editorial Reviews:

Often praised for their powerful engines, capable suspension, and strong performance in their respective classes.