KTM 250 400 450 520 525 SX MXC EXC 2000 Repair Service

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This manual covers the KTM SX, MXC, and EXC models from the year 2000, equipped with engine variants including 250cc, 400cc, 450cc, 520cc, and 525cc. These motorcycles are engineered for...

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Type: Motorcycle

Vendor:

Sku: 57858

Tags: 2000 250 400 450 520 525 EXC KTM Motorcycle Motorcycles MXC SX

Product variants

Description

This manual covers the KTM SX, MXC, and EXC models from the year 2000, equipped with engine variants including 250cc, 400cc, 450cc, 520cc, and 525cc. These motorcycles are engineered for demanding off-road competition, including Motocross (SX), Off-road Competition (MXC), and Enduro (EXC) disciplines. KTM's legacy in off-road racing is evident in these models, which feature a chromium-molybdenum steel trellis frame for strength and rigidity, and hydraulic disc brakes for superior stopping power in challenging conditions. The 2000 era models represented a significant advancement in KTM's dirt bike technology, focusing on refined power delivery and enhanced reliability. This comprehensive English-language repair service manual provides detailed, step-by-step instructions for maintenance and repair procedures. It covers all major systems, including the engine, transmission, chassis, electrical system, brakes, and fuel system, with specific guidance on component disassembly, repair, and reassembly. The manual includes critical technical specifications, torque values, fluid capacities, and diagnostic information to assist professional technicians and knowledgeable DIY enthusiasts. Its purpose is to enable informed decision-making for upkeep and repairs, imparting factory-level knowledge for optimal performance and longevity of your KTM motorcycle.

🏷️ Basic Information

Identification

Make:

Model:

SX, MXC, EXC

Year:

Engine Variants:

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

👋 Introduction

Market Position

Target Audience:

Professional technicians and knowledgeable DIY enthusiasts undertaking repairs and maintenance.

Key Features

Content Focus:

Detailed step-by-step repair procedures, critical specifications, illustrations, and diagnostic information.

Value Proposition

Benefit:

Enables informed decision-making for maintenance and repair, teaching factory-level knowledge.

📋 Manual Details

Coverage Areas

Bike Types:

Motocross (SX), Off-road Competition (MXC), Enduro (EXC)

Page Count

Estimated Page Count:

Likely over 300 pages, typical for a comprehensive service manual covering multiple variants.

Manual Type

Type:

Repair Service Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, top-end and bottom-end rebuilds, carburetor tuning, cooling system, lubrication system.

Transmission:

Clutch operation, gear shifting mechanisms, transmission disassembly and assembly, lubrication.

Chassis:

Frame inspection and repair, suspension (front forks, rear shock), steering head bearings, wheel bearings.

Electrical:

Ignition system, lighting, battery maintenance, wiring diagrams, troubleshooting electrical faults.

Brakes:

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

Fuel System:

Fuel tank, fuel lines, fuel filter, carburetor specifications and adjustments.

Procedures Included

Maintenance:

Regular servicing, oil changes, filter replacements, chain adjustment, pre-ride inspections.

Repair:

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

Troubleshooting:

Diagnostic procedures for common problems, fault finding charts.

Specifications:

Torque values, clearances, fluid capacities, electrical resistance.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers detailed engine rebuilds and advanced diagnostics.

📊 Manual Specifications

File Format

File Type:

Print Quality

Print Capability:

Full Printable

Zoom Capability

Zoom Functionality:

YES (Zoom IN/OUT)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

Compatibility

Operating System Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine Variants

Engine Types:

Four-stroke single-cylinder (expected for the era and model line)

Performance General

Tuning Focus:

Engine tuning and optimization for various disciplines (motocross, enduro).

Fuel System

Carburetor Type:

Likely Keihin or Mikuni carburetors, with specific model and jetting details provided in the manual.

🔧 Transmission

Standard Transmission

Type:

Likely 6-speed constant mesh manual transmission for off-road performance.

Features

Clutch Type:

Hydraulic actuated multi-plate wet clutch system.

📐 Dimensions

Weights

Dry Weight Range:

Varies by displacement and model, generally in the 100-120 kg range (dry).

🛡️ Safety Features

Active Features

Braking System:

Hydraulic disc brakes front and rear, designed for strong stopping power in off-road conditions.

Passive Features

Frame Construction:

Chromium-molybdenum steel trellis frame for torsional rigidity and impact resistance.

💡 Technology Features

Infotainment

Features:

Minimal to none, focusing on core performance and rider feedback. Digital displays or simple analog speedometers/odometers are typical.

Driver Assistance

Features:

None. Focus is on direct rider control and mechanical feedback.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10-15 hours of riding or as specified by the manual, depending on riding conditions.

Fluid Specifications

Engine Oil:

Refer to manual for specific viscosity (e.g., Motorex 10W/50 or similar high-quality motorcycle oil). Dual-clutch lubrication/transmission oil specification will also be detailed.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Piston rings, valve seals, clutch plates, wheel bearings, and chain/sprockets are common wear items in this model generation.

Carburetor Cleaning:

Regular cleaning and rebuilding of the carburetor is often necessary for optimal performance due to fuel quality and off-road use.

📚 Vehicle History

Brand Heritage

Ktm Legacy:

KTM is renowned for its off-road racing heritage and performance-oriented motorcycles.

Model Evolution

2000 Era Design:

The 2000 models represented a significant evolution in KTM's dirt bike technology, focusing on improved power delivery, handling, and reliability.

🏆 Awards & Recognition

Recognitions

Industry Standing:

KTM motorcycles of this era were highly regarded in off-road racing circles for their performance and durability.