🏷️ Basic Information

Make:

KTM

Model:

SX / EXC

Covered Years:

2000-2006

Engine Displacements Covered:

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

Manual Product Name:

Ktm 250 400 450 520 525 Sx Exc 2000 2006 Service Manual PDF Download

👋 Introduction

Category:

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

Competitors:

Yamaha YZ/WR series, Honda CR/CRF series, Suzuki RM/RMX series, Kawasaki KX/KDX series

Performance Focus:

Known for powerful engines, lightweight chassis, and aggressive styling.

Off Road Capability:

Designed for extreme off-road conditions, sand, mud, and rough terrain.

Manual Benefit:

Essential for DIY maintenance and repair, saving significant costs compared to professional service.

📋 Manual Details

General Coverage:

Complete vehicle from start to finish

Specific Coverage List:

General Information, Routine Maintenance, Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Transmission, Drive Chain & Sprockets, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting

Estimated Page Count:

Exact page count not provided, but described as an 'absolute wealth of information'.

Type:

Factory Service Workshop Repair Manual

Language:

English

File Format:

PDF

Compatibility:

All Versions of Windows & Mac

Requirements:

Adobe PDF Reader

Printability:

All pages are printable

Access:

Instant PDF download, providing immediate access to repair information.

📖 Manual Coverage

Engine Systems:

Engine Removal/Installation, Fuel System, Lubrication & Cooling, Engine Specifications, Intake & Exhaust

Drivetrain Systems:

Transmission, Drive Chain & Sprockets

Chassis Systems:

Steering System, Shocks, Body Work

Electrical Systems:

Electrical System

Suspension Details:

Front forks (e.g., WP USD forks) and rear shock absorber specifications, adjustments, and service procedures.

Frame And Subframe:

Inspection, maintenance, and repair of the frame, swingarm, and subframe.

Maintenance Procedures:

Routine Maintenance, Recommended Service Intervals (implied)

Repair Procedures:

Engine Repair, Transmission Repair, Steering System Repair, Suspension (Shocks) Repair, Body Work Repair, Electrical System Troubleshooting and Repair

Diagnostic Procedures:

Advanced Troubleshooting

Troubleshooting Methodology:

Systematic approach to diagnosing common and complex issues, including electrical gremlins and engine performance problems.

Engine Rebuild:

Comprehensive instructions for engine disassembly, inspection, component replacement, and reassembly for full rebuilds.

Depth:

Professional mechanic level, covering comprehensive servicing and repair.

📊 Manual Specifications

Format:

PDF

Searchability:

PDF format typically allows for text search, enhancing usability.

Quality:

High-quality digital reproduction, suitable for printing.

Binding:

N/A (Digital PDF format)

Paper:

N/A (Digital PDF format, printable on user-selected paper)

⚙️ Engine Specifications

Engine Type General:

Single-cylinder, 4-stroke engines.

Engine Configurations:

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

Power Delivery:

Emphasis on strong mid-range and top-end power for competition.

Cooling System:

Liquid-cooled (typical for these models)

Carburetor Type:

Likely Keihin (common for KTM during this era), specific model/size will be in manual.

Valve Train:

DOHC (Dual Overhead Camshaft)

Piston Design:

Manual will detail piston types (e.g., forged), ring specifications, and piston-to-cylinder clearance.

Oil System:

Dedicated oil sump with oil filter (details provided in manual).

🔧 Transmission

Type:

5-speed manual transmission.

Gear Ratios:

Specific gear ratios for each engine displacement are detailed in the manual.

Clutch Type:

Hydraulically actuated wet multi-plate clutch (typical for KTM).

Fluid Type:

Manual will specify appropriate transmission oil/ATF. Typically SAE 10W/10W-40, or specific KTM-recommended fluids.

Final Drive:

O-ring sealed drive chain and sprockets.

📐 Dimensions

Dry Weight Estimate:

Varies by model/displacement, typically in the range of 230-250 lbs (approx. 104-113 kg) for 4-stroke SX/EXC models of this era. Exact figures will be in the manual.

🛡️ Safety Features

Safety Standard:

Off-road competition vehicles, not typically rated by consumer safety organizations like NHTSA or Euro NCAP.

Braking System:

Hydraulic disc brakes (front and rear). Manual covers brake caliper, master cylinder, fluid, and pad maintenance/replacement.

Frame Construction:

Chromoly steel frame (typical for KTM).

💡 Technology Features

Features:

N/A (Performance off-road motorcycles, typically minimal rider electronics beyond basic instrumentation).

Features:

N/A

Ignition System:

Digital CDI (Capacitor Discharge Ignition), manual covers ignition timing, spark plug specifications, and troubleshooting.

🔧 Maintenance

Routine Maintenance:

Manual provides detailed schedules for tasks like oil changes, filter cleaning/replacement, chain adjustment, valve checks, spark plug replacement, etc., specific to operating hours or mileage.

Engine Oil Type:

Manual will specify KTM-recommended oil grades (e.g., SAE 10W-50, 10W-40, or specific formulations for wet clutches).

Coolant Type:

Manual will specify the type of coolant (e.g., ethylene glycol-based antifreeze with corrosion inhibitors).

Brake Fluid Type:

DOT 4 brake fluid (typical).

Fork Oil Type:

Manual will specify the type and viscosity of fork oil, and oil level for suspension service.

Common Wear Items:

Manual will cover inspection and replacement of wear items such as piston rings, valve guides, clutch plates, wheel bearings, fork seals, and swingarm bushings.

Importance:

Crucial for maintaining performance and longevity of high-performance off-road engines.

📚 Vehicle History

Manufacturer:

KTM AG, Austrian manufacturer renowned for off-road motorcycles.

Sx Exc Lineage:

The SX (Motocross) and EXC (Enduro) lines are KTM's flagship off-road offerings, evolving significantly throughout the late 90s and early 2000s, including engine updates and chassis improvements.

Manufacturing Location:

Austria

🏆 Awards & Recognition

Racing Heritage:

KTM's SX and EXC models have a strong heritage in professional motocross and enduro racing, often winning championships.

Customer Satisfaction:

Generally high customer satisfaction for KTM off-road bikes due to performance and build quality.