KTM 250 400 450 520 525 SX MXC EXC RACING 4-STROKE 2000 2001 2002 2003 Workshop Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 91900

Tags: 2000 2001 2002 2003 250 4-STROKE 400 450 520 525 EXC KTM Misc Motorcycle Motorcycles MXC RACING SX

Product variants

Description

This manual covers SX, MXC, and EXC Racing series motorcycles from the 2000-2003 model years, equipped with 4-stroke engines. These high-performance off-road motorcycles are renowned for their advanced chassis technology and 'Ready to Race' philosophy, making them a dominant force in motocross, enduro, and cross-country competition. The SX models are purpose-built for motocross, the MXC variants are designed for cross-country events, and the EXC models offer enduro capabilities, often including street-legal features for versatility. With their agile handling and powerful engines, these motorcycles are favored by enthusiasts and professional racers alike for their reliability and competitive edge. This comprehensive Workshop Service Repair Manual provides essential technical data and step-by-step instructions for maintaining and repairing your motorcycle. It covers all major systems, including the engine, transmission, chassis, electrical components, and braking system, detailing everything from routine maintenance, oil changes, and filter replacements to complete engine overhauls and component rebuilds. The manual also includes troubleshooting guidance for common issues, ensuring that owners, mechanics, and technicians can efficiently diagnose and resolve problems, optimize performance, and extend the lifespan of their vehicle.

🏷️ Basic Information

Identification

Make:

Model:

SX, MXC, EXC Racing

Engine Type:

4-Stroke

Applicable Years:

2000, 2001, 2002, 2003

Codes

Motorcycle Segment:

Off-Road / Dual-Sport / Motocross / Enduro

👋 Introduction

Market Position

Segment:

High-performance off-road motorcycles.

Target Audience:

Motocross, enduro, and off-road enthusiasts, mechanics, and service centers.

Competitive Analysis

Competitors:

Yamaha YZ/WR series, Honda CRF/XR series, Suzuki RM/DR series, Kawasaki KX/KLX series.

Key Features

Manufacturer Focus:

KTM is renowned for its 'Ready to Race' philosophy, emphasizing performance and advanced chassis technology.

Manual Value Proposition:

Provides essential technical data for DIY maintenance, repairs, and performance tuning, saving on professional service costs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service Repair

Page Count

Estimated Page Count:

300-500 (typical for this era and model complexity)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor), ignition system.

Transmission:

Gearbox operation, inspection, repair, clutch service, maintenance.

Chassis:

Frame inspection, suspension (forks, rear shock), steering system, wheel bearings, swingarm.

Electrical:

Wiring diagrams, lighting system, ignition coil, stator, battery maintenance, starter system (if applicable).

Braking System:

Hydraulic brake system (front and rear), caliper service, pad replacement, fluid bleeding, rotor inspection.

Fuel System:

Carburetor identification, disassembly, cleaning, adjustment, jetting, fuel tank, petcock.

Exhaust System:

Muffler, header pipe inspection and maintenance.

Procedures Included

Maintenance:

Routine maintenance, oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks.

Troubleshooting:

Common problems, diagnostic procedures for engine performance, electrical issues, starting problems.

Repair:

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

Rebuilds:

Detailed procedures for engine top-end rebuilds, carburetor rebuilds.

Technical Depth

Depth:

Comprehensive, covering everything from basic scheduled maintenance to complete engine and component overhauls.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text enabled for quick information retrieval.

Printability:

Printable pages for physical reference.

Print Quality

Image Resolution:

High-resolution, clear illustrations and diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Configuration:

Single-cylinder, 4-stroke

Engine Configuration

Bore X Stroke 250:

Approx. 76 mm x 54.8 mm

Bore X Stroke 400:

Approx. 87 mm x 65.5 mm

Bore X Stroke 450:

Approx. 95 mm x 63.4 mm

Bore X Stroke 520/525:

Approx. 95 mm x 72 mm (525cc variant)

Performance

Horsepower Range:

Estimated 40-55+ HP (depending on displacement and model variant)

Torque Range:

Estimated 35-45+ Nm (depending on displacement and model variant)

Fuel System

Carburetor Type:

Keihin FCR (Flat CR)

Carburetor Sizes:

Typically 39mm or 41mm FCR

Cooling System

Type:

Liquid-cooled

Lubrication

Oil Type Specification:

SAE 10W-40 or 15W-50 semi-synthetic or fully synthetic motorcycle oil, API SG or higher.

Valve Train

Configuration:

DOHC (Double Overhead Camshaft), 4 valves per cylinder

🔧 Transmission

Standard

Type:

Constant mesh, 5-speed

Features

Clutch Type:

Wet, multi-plate, hydraulically operated

Fluid Specifications

Transmission Oil Type:

Dedicated transmission oil or engine oil meeting specific viscosity and API rating (refer to manual for exact specs).

📐 Dimensions

Exterior

General Classification:

Compact, agile off-road motorcycle chassis.

Weights

Dry Weight Range:

Approx. 105-115 kg (depending on model and displacement)

Wet Weight Estimate:

Approx. 115-125 kg (with fluids)

🛡️ Safety Features

Ratings

Safety Standards:

Designed for off-road competition and recreational use; not typically subject to road-legal safety ratings.

Active Features

Braking Performance:

High-performance hydraulic disc brakes (front and rear) for reliable stopping power.

Passive Features

Chassis Design:

Strong, lightweight chromoly steel frame provides rigidity and impact absorption.

💡 Technology Features

Infotainment

Features:

Minimal to no electronic infotainment features; focus is on performance and rider engagement.

Driver Assistance

Features:

No electronic driver assistance features (e.g., ABS, traction control) on standard models of this era.

Connectivity

Features:

No electronic connectivity features.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 10-15 hours of riding or annually, whichever comes first.

Oil Filter Replacement:

Concurrent with engine oil changes.

Air Filter Cleaning:

Every 5-10 hours of riding, or more frequently in dusty conditions.

Valve Clearance Check:

Every 20-30 hours of riding or annually.

Spark Plug Replacement:

Every 20-30 hours of riding.

Fluid Specifications

Coolant Type:

Ethylene glycol based coolant (e.g., Motorex Coolant M3.0) mixed with distilled water at a 50/50 ratio.

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid.

Clutch Fluid Type:

Mineral oil (for some older models) or DOT 4 brake fluid (for hydraulic systems), verify with manual.

Known Issues

Carburetor Jetting:

May require jetting adjustments based on altitude, temperature, and modifications.

Clutch Wear:

Diaphragm spring or clutch plate wear can occur with aggressive use.

Suspension Seals:

Fork seals and shock seals may require replacement over time due to riding conditions.

Engine Timing Chain:

Regular checks for tension and wear are recommended.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

KTM (Kronreif & Trunkenpolz Mattighofen) is an Austrian manufacturer founded in 1934.

Motorsport Focus:

KTM has a long and successful history in off-road motorsports, including motocross and enduro.

Model Evolution

Sx Series:

Motocross competition bikes.

Mxc Series:

Cross-country competition bikes, often with larger fuel tanks and lighting for extended events.

Exc Series:

Enduro competition bikes, typically street-legal in many markets with features for off-road riding and occasional road use.

Production

Production Period:

These models represent a significant generation of KTM's 4-stroke off-road platform.

🏆 Awards & Recognition

Recognitions

Motorsport Success:

KTM models of this era have a strong track record of success in professional motocross and enduro racing series.

Ratings

Review Sentiment:

Generally highly regarded for their performance, power, and handling in the off-road community.

Certifications

Emissions Compliance:

Designed for off-road use; may not meet stringent road-legal emissions standards in all regions.