KTM 25 400 450 525 SX EXC Motorcycle 2000-2007 Service Repair Workshop Manual Pdf

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Type: Motorcycle

Vendor:

Sku: 92108

Tags: 2000 2001 2002 2003 2004 2005 2006 2007 25 SX 400 EXC 400 SX 450 EXC 450 SX 525 EXC 525 SX KTM Misc Motorcycle Motorcycles

Product variants

Description

This manual covers the SX and EXC series motorcycles produced between 2000 and 2007, featuring the RFS engine platform across various displacements including 400cc, 450cc, and 525cc models. The renowned 'Ready to Race' philosophy is evident in these high-performance off-road machines, designed for competitive motocross and demanding enduro riding. These models are celebrated for their powerful engines, agile handling, and robust construction, making them a popular choice for both professional racers and dedicated off-road enthusiasts seeking exceptional performance and rider engagement. This comprehensive factory service repair workshop manual provides detailed instructions for maintaining and repairing your SX or EXC motorcycle. It covers all essential systems, including engine mechanicals, fuel and ignition systems, cooling, transmission, suspension, braking, and electrical components. The manual includes step-by-step procedures for routine maintenance, engine rebuilds, suspension servicing, and electrical diagnostics, along with troubleshooting guides and technical specifications. Its thorough coverage ensures owners and technicians can effectively perform all necessary service and repair operations, maximizing the longevity and performance of the vehicle.

🏷️ Basic Information

Identification

Make:

Model:

SX / EXC

Product Name:

KTM 25 400 450 525 SX EXC Motorcycle 2000-2007 Service Repair Workshop Manual Pdf

Codes

Engine Codes Implied:

RFS (Ready For Suspension) engine platform across various displacements

👋 Introduction

Market Position

Segment:

High-performance off-road motorcycles (Motocross and Enduro)

Target Audience:

Competitive racers, serious off-road enthusiasts, professional mechanics specializing in KTM motorcycles.

Competitive Analysis

Competitors:

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

Key Features

Vehicle Philosophy:

KTM's 'Ready to Race' philosophy emphasizing performance, power, and rider engagement.

Manual Benefit:

Enables owners to perform complex maintenance and repairs, reducing reliance on dealerships and extending the life of the vehicle.

📋 Manual Details

Coverage Areas

Model Years Covered:

2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

Model Variants Covered:

SX (Motocross), EXC (Enduro/Cross-Country)

Engine Displacements Covered:

250cc (implied, common in SX line), 400cc, 450cc, 525cc

Page Count

Estimated Page Count:

High (typically 300-600+ pages for comprehensive factory manuals)

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly and reassembly of engine, cylinder head, valve train, piston, connecting rod, crankshaft, transmission, clutch, lubrication system.

Fuel System:

Carburetor (Mikuni, Keihin) tuning, cleaning, and overhaul; fuel pump (if applicable); fuel tank and lines.

Ignition System:

Ignition timing, CDI unit, stator, ignition coil, spark plug specifications and testing.

Cooling System:

Radiator, coolant hoses, water pump, thermostat specifications and maintenance.

Transmission And Drivetrain:

Gearbox inspection, repair, and adjustment; clutch operation and maintenance; chain and sprockets; final drive.

Suspension Front:

Front fork (WP) disassembly, reassembly, oil types, levels, pressure adjustments, seal replacement, and internal component servicing.

Suspension Rear:

Rear shock absorber (WP) servicing, linkage maintenance, spring preload adjustment, damping adjustments.

Braking System:

Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding and specifications, rotor inspection.

Electrical System:

Wiring diagrams, battery maintenance, lighting system, starter motor, switches, fuses, and troubleshooting electrical faults.

Frame And Bodywork:

Frame inspection, subframe, handlebars, seat, plastics, exhaust system removal and installation.

Wheels And Tires:

Wheel bearing inspection and replacement, spoke tensioning, tire pressure recommendations, rim maintenance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning, spark plug checks, valve clearance checks.

Troubleshooting:

Diagnostic flowcharts, common problems and their solutions, symptom-based troubleshooting guides.

Engine Rebuild:

Detailed instructions for top-end and bottom-end engine rebuilds, including torque specifications and clearances.

Suspension Servicing:

Step-by-step guides for fork and shock absorber overhaul, including fluid types and quantities.

Electrical Diagnostics:

Schematics, testing procedures for electrical components, fault finding for ignition and charging systems.

Chassis And Bodywork Repair:

Instructions for frame alignment checks, body panel removal/installation, exhaust system mounting.

Technical Depth

Depth Of Coverage:

Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts. Includes all aspects from routine maintenance to complete engine and chassis overhauls.

Diagnostic Capabilities:

Detailed diagnostic procedures, troubleshooting tables, and electrical schematics for accurate fault identification.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text-based PDF (assuming digital reproduction from original source)

Print Quality

Digital Quality:

High-resolution scans or digital native, ensuring clarity of diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke, liquid-cooled (RFS engine platform)

Bore X Stroke 400:

Approx. 84mm x 72mm (Typical for 400cc RFS)

Bore X Stroke 450:

Approx. 95mm x 63.4mm (Typical for 450cc RFS)

Bore X Stroke 525:

Approx. 95mm x 72mm (Typical for 525cc RFS)

Bore X Stroke 250:

Approx. 76mm x 54.8mm (Typical for 250cc 2-stroke, or specific 4-stroke variants)

Performance

Horsepower 450:

Estimated 50-55 HP (Varies by model year and tuning)

Torque 450:

Estimated 45-50 Nm (Varies by model year and tuning)

Fuel System

Carburetor Type:

Mikuni TMR Flatslide (common for this era) or Keihin FCR

Carburetor Size:

Typically 38mm or 39mm

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh sequential gearbox

Features

Clutch Type:

Hydraulically operated, multi-plate wet clutch

Gear Ratios:

Specific ratios vary by model year and SX/EXC designation; detailed in manual.

📐 Dimensions

Exterior

Wheelbase:

Varies by model, typically around 1470-1490mm

Weights

Dry Weight:

Varies by model, typically around 100-110 kg (excluding fuel and fluids)

Fuel Capacity:

Typically 7-9 liters

🛡️ Safety Features

Ratings

Safety Focus:

Off-road focused; safety primarily relates to handling, braking, and chassis stability.

Active Features

Braking System:

Hydraulic disc brakes, front and rear, with braided steel lines for improved feel and performance.

Passive Features

Frame Construction:

Chromoly steel trellis frame for strength and rigidity.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Race-oriented off-road motorcycle, no infotainment system)

Driver Assistance

Electronic Aids:

Minimal; primarily focused on mechanical performance. No ABS or traction control on these models.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 15-20 hours of riding or annually, depending on usage intensity.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours).

Valve Clearance Check:

Typically every 30-50 hours of riding.

Fluid Specifications

Engine Oil Type:

SAE 10W-50 or 15W-50, API SG/SH/SJ or JASO MA compliant motorcycle oil (check specific manual for exact spec).

Fork Oil Type:

WP Suspension specific fork oil (e.g., SAE 5W or 7.5W), with specific volume and pressure requirements.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Cam Chain Tensioner:

Early RFS models could have issues with the automatic cam chain tensioner, sometimes requiring replacement with a manual tensioner.

Clutch Slave Cylinder:

Potential for seal failure in the hydraulic clutch slave cylinder.

Radiator Leaks:

Common to many off-road bikes; susceptible to damage from impacts.

📚 Vehicle History

Brand Heritage

Brand Focus:

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

Model Evolution

Rfs Engine:

The RFS (Ready For Suspension) engine platform introduced in the late 90s represented a significant advancement, known for its power delivery and reliability.

Sx Vs Exc:

SX models are purpose-built for motocross, featuring stiffer suspension and often higher performance tuning. EXC models are homologated for road use (in many markets) and feature wider-ratio gearboxes, lights, and more compliant suspension for enduro riding.

Production

Manufacturing Location:

Austria (Primary)

🏆 Awards & Recognition

Recognitions

Motorsport Success:

KTM SX and EXC models have a long history of success in motocross and enduro racing championships worldwide.