KTM 250 400 450 520 525 SX EXC Motorcycle 2000-2006 Service Repair Workshop Manual

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Type: Motorcycle

Vendor:

Sku: 100655

Tags: 2000 2001 2002 2003 2004 2005 2006 250 EXC 250 SX 400 EXC 400 SX 450 EXC 450 SX 520 EXC 520 SX 525 EXC 525 SX KTM Misc Motorcycle Motorcycles

Product variants

Description

This manual covers the SX/EXC Series motorcycles, including the 250, 400, 450, 520, and 525 models produced between 2000 and 2006. These high-performance off-road machines are renowned for their powerful four-stroke engines, agile handling, and competitive racing heritage. The SX variants are designed for motocross, while the EXC models cater to enduro riding with added features like lighting. The strong reputation in motorsports, often summarized as 'Ready To Race,' is reflected in the engineering and capabilities of these motorcycles, making them a popular choice for both competition and demanding recreational use. This comprehensive Factory Service Repair Workshop Manual provides detailed instructions and specifications essential for maintaining, diagnosing, and repairing your SX/EXC motorcycle. It covers all major systems, including the engine, transmission, electrical components, chassis, brakes, and fuel system. Within its extensive pages, you will find step-by-step procedures for scheduled maintenance, complete engine and gearbox overhauls, troubleshooting common issues, and detailed technical specifications. This manual is an invaluable resource for owners and technicians aiming to ensure optimal performance, reliability, and longevity of these specialized off-road vehicles.

🏷️ Basic Information

Identification

Make:

Model:

SX/EXC Series

Model Variant:

250, 400, 450, 520, 525

Codes

Product Name:

KTM 250 400 450 520 525 SX EXC Motorcycle 2000-2006 Service Repair Workshop Manual

👋 Introduction

Market Position

Segment:

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

Competitive Analysis

Competitors:

Yamaha YZ/WR series, Honda CRF/CR series, Suzuki RM/RMX series, Kawasaki KX/KDX series during the same production years.

Key Features

Vehicle Focus:

Known for their powerful engines, agile handling, and competitive racing heritage. SX models are motocross-oriented, EXC models are enduro-focused with lights and wider gear ratios.

Manual Value

Benefit:

Essential for owners and mechanics to maintain, diagnose, and repair these specialized motorcycles, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Areas

Covered Years:

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

Page Count

Estimated Page Count:

Extensive (Typical factory service manuals for this era range from 300-600+ pages)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, tuning, diagnosis, lubrication system, cooling system, exhaust system

Transmission:

Gearbox inspection, repair, clutch operation, lubrication

Electrical:

Ignition system, lighting, charging system, battery, wiring diagrams, starter motor

Chassis:

Frame, suspension (forks, rear shock), steering, wheels, hubs, spokes, bearings

Brakes:

Hydraulic brake system (front and rear calipers, master cylinders, lines), brake fluid specifications and bleeding procedures

Fuel System:

Carburetor (Keihin specific to models/years), fuel pump, fuel tank, fuel lines, jetting information

Bodywork:

Plastics, seat, fenders, fuel tank cover, graphics, mounting procedures

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault finding trees

Repair:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, assembly, and installation

Diagnostics:

Detailed diagnostic charts and flowcharts for electrical and mechanical issues

Technical Depth

Depth:

Comprehensive: Covers everything from basic fluid changes to full engine and transmission rebuilds, including detailed torque specifications and tolerances.

📊 Manual Specifications

File Format

Quality:

High-resolution PDF, ensuring clear diagrams and text. Searchable text for easy navigation.

Print Quality

Printability:

Printable format allows for easy printing of specific sections or the entire manual.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

Four-stroke, single-cylinder (liquid-cooled)

Bore X Stroke 250:

Typically around 72 mm x 60 mm (subject to specific model year variations)

Bore X Stroke 400:

Typically around 84 mm x 72 mm (subject to specific model year variations)

Bore X Stroke 450:

Typically around 95 mm x 63.4 mm (subject to specific model year variations)

Bore X Stroke 525:

Typically around 95 mm x 72 mm (subject to specific model year variations)

Performance

Horsepower Range:

Approx. 40-60 HP (depending on displacement and model year)

Torque Range:

Approx. 35-50 ft-lbs (depending on displacement and model year)

Fuel System

Carburetor Type:

Keihin FCR (Flat CR) series carburetors, typically 39mm or 41mm depending on model and year.

Ignition Type:

Digital CDI (Capacitor Discharge Ignition) with variable ignition timing.

🔧 Transmission

Standard

Type:

Constant-mesh, sequential 6-speed gearbox.

Optional

Availability:

N/A (Standard for this era and model line)

Features

Clutch Type:

Hydraulically operated multi-plate wet clutch.

📐 Dimensions

Exterior

Typical Seat Height:

High (approx. 37-38 inches / 940-965 mm, depending on model and suspension setup)

Weights

Dry Weight Range:

Approx. 230-250 lbs (104-113 kg), depending on model and displacement.

Fuel Capacity:

Typically around 2.5-3.5 gallons (9.5-13 liters), depending on model (SX vs EXC).

🛡️ Safety Features

Ratings

Classification:

Off-road competition and recreational use. No DOT or NHTSA ratings apply.

Active Features

Braking System:

High-performance hydraulic disc brakes (front and rear) with stainless steel braided lines common on later models.

Passive Features

Protective Gear Recommendation:

Manual will emphasize the critical importance of wearing appropriate protective gear (helmet, goggles, boots, gloves, body armor).

💡 Technology Features

Infotainment

Features:

Minimal. Focus is on performance and off-road capability. Basic digital hour meter/odometer typically present.

Driver Assistance

Features:

None. These are pure performance machines designed for rider control and feedback.

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Frequency:

Typically every 10-15 hours of riding or annually. Manual will specify exact intervals based on riding conditions.

Air Filter Cleaning:

Recommended after every few rides, or more frequently in dusty conditions. Detailed cleaning and oiling procedures provided.

Valve Clearance Check:

Typically every 40-60 hours of riding. Critical for engine performance and longevity.

Fluid Specifications

Engine Oil:

Typically a high-quality 10W-50 or 10W-60 synthetic motorcycle oil meeting JASO MA standards. Specific grades will be listed in the manual.

Transmission Oil:

Often shares engine oil, but manual will confirm capacity and specific type if different. Some models might have a separate gearbox oil.

Coolant:

A 50/50 mix of distilled water and a quality motorcycle antifreeze/coolant (ethylene glycol based). Specific KTM part numbers or equivalent may be recommended.

Brake Fluid:

DOT 4 or DOT 5.1 hydraulic brake fluid. Manual will specify.

Known Issues

Common Wear Items:

Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings, swingarm bearings, chain and sprockets, fork seals.

Specific Concerns:

Early models might have potential issues with certain engine components or electrical connections; the manual provides diagnosis and repair procedures for these.

📚 Vehicle History

Brand Heritage

Reputation:

KTM has a strong heritage in off-road motorsports, particularly motocross and enduro, often referred to as 'Ready To Race'.

Model Evolution

Development:

These models represent KTM's evolution in the four-stroke off-road segment, building on earlier designs and introducing advancements in chassis and engine technology.

Production

Manufacturing Location:

Austria (KTM Sportmotorcycle AG)

🏆 Awards & Recognition

Recognitions

Motorsports Success:

KTM models of this era achieved significant success in various off-road racing disciplines, including AMA Supercross, Motocross, and GNCC (Grand National Cross Country).

Ratings

Industry Perception:

Highly regarded for their performance, handling, and durability in demanding off-road conditions.