KTM 250EXC 450SX MXC EXC 525SX MXC EXC owners Manual.2004

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🏷️ Basic Information Identification Make: KTM Model: 250 EXC, 450 SX, 450 MXC, 450 EXC, 525 SX, 525 MXC, 525 EXC Year: 2004 Codes Platform Code: Varies by specific model...

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Taper: Motorcycle

Distributeur:

UGS: 71958

Mots clés: 2004 250EXC 450 450SX 525SX KTM Motorcycle Motorcycles MXC EXC

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Model:

250 EXC, 450 SX, 450 MXC, 450 EXC, 525 SX, 525 MXC, 525 EXC

Year:

Codes

Platform Code:

Varies by specific model variant (e.g., EXC platform, SX platform)

Engine Code 250:

Likely LC4 or similar single-cylinder designation for EXC models

Engine Code 450 525:

Likely LC4 V-twin or large single-cylinder designation for SX/MXC/EXC models

👋 Introduction

Market Position

Vehicle Class:

High-performance off-road motorcycles (Enduro, Motocross, Supermoto variants).

Target Audience:

Enthusiast riders focused on off-road competition, trail riding, and extreme sports.

Competitive Analysis

Key Competitors:

Yamaha WR series, Honda CR-FX series, Suzuki RMX series, Husqvarna TE series.

Key Features

Kتم Brand Philosophy:

Ready to Race - focus on performance, lightweight design, and robust components.

Model Variations:

The manual covers a range of displacements and intended uses (EXC for Enduro, SX/MXC for Motocross/Cross-Country).

📋 Manual Details

Coverage Areas

Manual Coverage Scope:

Comprehensive owner's manual covering operation, maintenance, and basic adjustments for multiple 2004 KTM models.

Page Count

Estimated Page Count:

Approximately 150-250 pages (estimated for comprehensive owner's manuals of this era).

Manual Type

Manual Type:

Owner's Manual

Language

Language:

English (assumed, typical for international sales)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Cooling system, lubrication system, fuel system (carburetor), ignition system, starting system.

Transmission Drivetrain:

Clutch operation, gearbox function, final drive chain maintenance.

Chassis Suspension:

Front fork operation and basic adjustments, rear shock absorber operation, frame, swingarm, and linkage maintenance.

Brakes:

Hydraulic brake system operation (front and rear), brake fluid checks and replacement procedures.

Electrical:

Lighting system, battery maintenance, basic electrical component identification.

Controls Instruments:

Handlebar controls, dashboard indicators, instrument cluster functions.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air), spark plug inspection, chain adjustment, lubrication points.

Inspections Adjustments:

Pre-ride checks, brake lever and pedal adjustments, clutch lever adjustment, suspension sag adjustment (basic).

Troubleshooting:

Basic troubleshooting guides for common operational issues.

Safety Information:

Safe riding practices, protective gear recommendations, general warning notices.

Technical Depth

Depth Of Coverage:

Owner-level maintenance and basic operational guidance. Does not include detailed engine teardown or complex electronic diagnostics.

📊 Manual Specifications

File Format

File Format Type:

PDF (Portable Document Format)

Searchability:

Typically searchable text within PDF format, allowing for quick information retrieval.

Print Quality

Print Quality Recommendation:

High resolution for clear diagrams and text, suitable for printing.

Binding Type

Binding Type If Printed:

Not applicable (digital format), but original manuals were typically saddle-stitched or perfect bound.

Paper Type

Paper Type If Printed:

Not applicable (digital format), but original manuals often used durable, gloss paper.

⚙️ Engine Specifications

Primary Engine 250

Engine Type 250:

Likely a 249cc (approx.) single-cylinder, four-stroke engine.

Primary Engine 450 525

Engine Type 450 525:

Likely a 449cc (for 450 models) or 510cc (for 525 models) single-cylinder, four-stroke engine (LC4 platform).

Performance 250

Horsepower 250 Estimated:

Approximately 30-40 HP (estimated, specific output varies by tuning and model).

Performance 450 525

Horsepower 450 Estimated:

Approximately 45-55 HP (estimated, specific output varies by tuning and model).

Horsepower 525 Estimated:

Approximately 50-60 HP (estimated, specific output varies by tuning and model).

Fuel System

Fuel Delivery:

Carburetor (e.g., Keihin FCR series).

Fuel Type:

Unleaded gasoline (RON 91 or higher).

Cooling System

Cooling Method:

Liquid-cooled.

Lubrication

Oil Type:

High-quality motorcycle specific 4-stroke engine oil (e.g., SAE 10W-40 or 10W-50, JASO MA rated).

Oil Capacity 250

Oil Capacity Engine 250:

Approximately 1.0 - 1.2 liters (check manual for exact specification).

Oil Capacity 450 525

Oil Capacity Engine 450 525:

Approximately 1.2 - 1.5 liters (check manual for exact specification).

Spark Plug

Spark Plug Type:

NGK (e.g., CR9E, CR10E) or equivalent, specific type to be confirmed in manual.

🔧 Transmission

Standard

Transmission Type:

6-speed manual transmission.

Optional

Optional Gearbox:

Not applicable (standard 6-speed).

Features

Clutch Type:

Hydraulic actuated, multi-plate wet clutch.

Gearbox Oil Type:

Separate gearbox oil may be specified, or shared with engine oil depending on exact design (check manual).

📐 Dimensions

Exterior 250Exc

Seat Height 250Exc Approx:

Approximately 950-960 mm (37.4-37.8 inches).

Exterior 450 525

Seat Height 450 525 Approx:

Approximately 960-970 mm (37.8-38.2 inches).

Weights 250Exc

Dry Weight 250Exc Approx:

Approximately 105-110 kg (231-242 lbs).

Weights 450 525

Dry Weight 450 525 Approx:

Approximately 110-120 kg (242-265 lbs).

Fuel Capacity

Fuel Tank Capacity Approx:

Approximately 7.5 - 9.5 liters (1.9 - 2.5 gallons), depending on model variant.

Wheels Tires

Front Wheel Size:

21 inches.

Rear Wheel Size:

18 inches.

Front Tire Size Spec:

Commonly 80/100-21, specific DOT rating recommended.

Rear Tire Size Spec:

Commonly 100/90-18 or 110/100-18, specific DOT rating recommended.

🛡️ Safety Features

Ratings

Safety Rating Classification:

N/A (Off-road motorcycles are not typically subject to automotive safety ratings like NHTSA or Euro NCAP).

Active Features

Braking System:

Hydraulic disc brakes front and rear (Brembo components often used).

Suspension Features:

Adjustable front forks (compression/rebound) and rear shock absorber (preload/rebound), contributing to stability and control.

Passive Features

Frame Design:

Chromoly steel trellis frame for strength and light weight.

Handguards:

Standard or optional handguards to protect levers and rider's hands.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic instrument cluster only).

Driver Assistance

Electronic Aids:

N/A (No electronic rider aids like ABS or traction control on these models).

Connectivity

Connectivity Features:

Instrumentation

Dashboard Features:

Speedometer, odometer, trip meter, neutral indicator, turn signal indicators, high beam indicator, engine warning light.

🔧 Maintenance

Service Intervals Oil

Engine Oil Change Interval:

Every 15-30 operating hours or annually (highly dependent on usage conditions, refer to manual).

Service Intervals Air Filter

Air Filter Cleaning Interval:

Every 5-10 operating hours or as needed, especially in dusty conditions.

Service Intervals Spark Plug

Spark Plug Inspection Interval:

Every 15-30 operating hours.

Service Intervals Chain

Chain Lubrication Adjustment Interval:

Every ride or as needed, check tension frequently.

Fluid Specifications

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Coolant Type:

Ethylene glycol based antifreeze coolant (e.g., Motorex Coolant M5.0).

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, chain and sprockets, fork seals, swingarm bushings.

Engine Specific Considerations:

Regular valve clearance checks are crucial for LC4 engines. Overheating can occur if cooling system is not maintained.

Electrical Considerations:

While generally robust, ensure battery terminals are clean and connections are secure. Charging system should be checked if battery issues arise.

📚 Vehicle History

Brand Heritage

Kتم Motorsports Legacy:

KTM has a long and successful history in off-road racing, including motocross, enduro, and rally raids, influencing the development of these models.

Model Evolution

Lc4 Platform Significance:

The LC4 engine platform, prevalent in the 450/525 models, is known for its torque and durability in demanding off-road conditions.

Production

Ktm Manufacturing Origin:

Austria.

🏆 Awards & Recognition

Recognitions

Kتم Offroad Dominance:

KTM is consistently recognized for its success in off-road racing championships, a testament to the performance capabilities of their models.

Ratings

Media Reviews 2004:

KTM off-road models from this era generally received praise for their powerful engines, advanced suspension, and competitive chassis.

Certifications

Emissions Compliance:

Compliance with relevant emissions standards for off-road vehicles in the target markets of 2004.