KTM 250-400-450-525 SX-EXC 2000-2007 Service Repair Workshop Manual Download PDF

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Basic Information Identification Make: KTM Model: SX Series, EXC Series Covered Models: 250, 400, 450, 525 Year Range: 2000-2007 Codes Vehicle Type: Off-Road Motorcycles (Motocross and Enduro) Introduction Market Position...

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Type: Motorcycle

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Sku: 82637

Tags: 2000 2001 2002 2003 2004 2005 2006 2007 250 EXC 250 SX 400 EXC 400 SX 450 EXC 450 SX 525 EXC 525 SX KTM Misc Motorcycle Motorcycles

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Description

Basic Information
Identification
Make:	KTM
Model:	SX Series, EXC Series
Covered Models:	250, 400, 450, 525
Year Range:	2000-2007
Codes
Vehicle Type:	Off-Road Motorcycles (Motocross and Enduro)

Introduction
Market Position
Category:	High-Performance Off-Road Motorcycles
Target Audience:	Motocross racers, enduro riders, off-road enthusiasts, and independent repair shops.
Competitive Analysis
Segment Competitors:	Yamaha YZ/WR series, Honda CRF/XR series, Suzuki RM/DR series, Kawasaki KX/KLX series, Husqvarna, Beta.
Key Features
Vehicle Strengths:	Lightweight chassis, powerful engines, advanced suspension, competitive performance in respective disciplines.
Manual Value Proposition:	Provides comprehensive technical data and procedures to maintain, troubleshoot, and repair these performance-oriented motorcycles, enabling owners to perform work equivalent to dealership service.

Manual Details
Coverage Areas
Manual Scope:	Complete Service, Repair, and Workshop Manual
Page Count
Estimated Pages:	Extensive (Specific page count not provided, but typical for comprehensive factory manuals)
Manual Type
Type:	Factory Service Manual / Workshop Manual
Language
Language:	English (Presumed, standard for downloadable manuals of this nature)
Format
Format:	PDF Download

Manual Coverage
Systems Covered
Engine Mechanics:	Engine disassembly, assembly, inspection, tuning, component replacement (pistons, rings, valves, crankshaft, connecting rods), cylinder head service, cooling system.
Fuel System:	Carburetor overhaul and adjustment (Mikuni, Keihin models typical), fuel pump (if applicable), fuel tank, fuel lines, filters.
Ignition System:	Ignition coil testing, spark plug selection and gapping, stator and rotor inspection, CDI unit troubleshooting, wiring diagrams.
Transmission Drivetrain:	Gearbox disassembly and assembly, clutch service (friction plates, steel plates, springs), chain and sprocket maintenance, final drive inspection.
Suspension:	Front fork service (oil changes, seal replacement, internal component inspection, spring rates), rear shock absorber service and adjustment, linkage maintenance.
Brakes:	Front and rear brake caliper overhaul, master cylinder service, brake pad replacement, brake fluid flush and bleed, rotor inspection.
Electrical System:	Wiring diagrams for lighting, horn, switches, battery maintenance, charging system, fuses, troubleshooting electrical faults.
Chassis Frame:	Frame inspection for damage, steering head bearing service, swingarm bearing maintenance, wheel bearing replacement.
Bodywork Plastics:	Removal and installation of body panels, seat, handlebars, controls.
Procedures Included
Routine Maintenance:	Oil and filter changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks, bolt torque checks.
Troubleshooting:	Diagnostic charts for common problems, fault finding procedures for engine, electrical, and chassis issues.
Repair Procedures:	Step-by-step instructions for component overhauls, replacements, and adjustments for all major systems.
Engine Rebuild:	Detailed instructions for complete engine disassembly, inspection of wear limits, and reassembly, including torque specifications.
Suspension Tuning:	Guidance on adjusting suspension settings for various riding conditions and rider weights.
Wiring Diagrams:	Comprehensive electrical schematics for each model variant.
Technical Depth
Depth Of Coverage:	Comprehensive. Covers everything from basic adjustments and fluid changes to complete engine and transmission rebuilds, electrical system diagnostics, and suspension tuning.

Manual Specifications
File Format
Compatibility:	Compatible with all standard PDF readers on computers, tablets, and smartphones.
Print Quality
Resolution:	High-resolution scans, ensuring clarity of text and diagrams for printing and on-screen viewing.
Binding Type
Digital Format:	N/A (Digital Download)
Paper Type
Digital Format:	N/A (Digital Download)

Engine Specifications
Primary Engine
Engine Type:	Four-stroke, single-cylinder (typically SOHC or DOHC depending on specific model year and displacement)
Bore X Stroke:	Varies by model (e.g., 250cc: ~76 x 54.9mm, 450cc: ~95 x 63.4mm, 525cc: ~97 x 70.8mm - indicative values, specific values in manual)
Displacement:	250cc, 400cc, 450cc, 525cc
Cooling System:	Liquid-cooled
Performance
Horsepower:	Estimated 35-55+ HP depending on model and tuning (specific figures in manual)
Torque:	Estimated 25-40+ lb-ft depending on model and tuning (specific figures in manual)
Fuel System
Carburetor Models:	Likely Mikuni or Keihin (e.g., VM, TM, PD, MX carburetors - specific model numbers in manual)
Fuel Type:	Unleaded gasoline (Octane rating typically 91 or higher)

Transmission
Standard
Type:	Constant-mesh, sequential manual transmission
Number Of Gears:	Typically 5 or 6 speed (specific count in manual)
Optional
Type:	N/A (Standard manual transmission)
Features
Clutch Type:	Wet, multi-plate clutch
Transmission Oil Type:	Specific motorcycle transmission oil (e.g., SAE 10W/40 or 15W/50, JASO MA certified - specific grade in manual)

Dimensions
Exterior
Wheelbase:	Varies by model and year (e.g., approx. 1470-1490 mm / 57.9-58.7 in - specific values in manual)
Weights
Dry Weight:	Varies by model and year (e.g., approx. 100-115 kg / 220-253 lbs - specific values in manual)

Safety Features
Ratings
Safety Standards:	N/A (Off-road vehicles typically do not have road safety ratings like NHTSA or Euro NCAP)
Active Features
Braking System:	Hydraulic disc brakes front and rear. Specific caliper and rotor sizes detailed in manual.
Passive Features
Frame Construction:	High-strength steel or aluminum alloy perimeter frame for rigidity and impact resistance.

Technology Features
Infotainment
Features:	N/A (No typical infotainment systems on these models, focus is on performance and function)
Driver Assistance
Features:	N/A (No electronic rider aids like ABS or traction control on these models)
Connectivity
Features:	N/A

Maintenance
Service Intervals
Engine Oil Change:	Typically every 10-20 hours of riding or as specified in the manual (e.g., 15 hours).
Air Filter Cleaning:	Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours).
Spark Plug Replacement:	As needed or every 20-40 hours of riding (specific plug type and gap in manual).
Valve Clearance Check:	Critical for performance and engine longevity, typically every 20-40 hours or annually.
Fluid Specifications
Engine Oil:	Specific viscosity and JASO MA rating (e.g., Motorex Power Synth 4T 10W-40, or equivalent from other reputable brands - full details in manual).
Coolant:	Ethylene glycol based antifreeze coolant, pre-mixed or with distilled water (50/50 ratio recommended) - specific type and capacity in manual.
Brake Fluid:	DOT 4 or DOT 5.1 brake fluid (verify in manual for specific type) for hydraulic systems.
Known Issues
Common Wear Items:	Clutch plates, piston and rings, valve guides, wheel bearings, steering head bearings, suspension seals due to high-stress off-road use.
Specific Concerns:	Early four-stroke KTMs could sometimes exhibit issues related to cam chain tensioners or specific carburetor jetting depending on altitude and conditions. Manual provides troubleshooting.

Vehicle History
Brand Heritage
Manufacturer:	KTM AG, Austria. Known for its 'Ready to Race' philosophy and dominance in off-road motorsports, particularly motocross and enduro.
Model Evolution
Sx Series:	KTM's motocross line, focused on competitive performance on closed circuits. Competes in 125cc, 250cc, and 450cc classes.
Exc Series:	KTM's Enduro line, designed for off-road trail riding and cross-country racing, often with features like lighting and broader powerbands. Competes in various displacement classes.
Production
Manufacturing Location:	Austria (primary)
Development Focus:	This era saw significant development in KTM's four-stroke engine technology and chassis design, solidifying their position in the off-road market.

Awards & Recognition
Recognitions
Motorsport Success:	KTM models from this era consistently achieved podium finishes and championships in various national and international motocross and enduro events.
Industry Reputation:	Highly regarded for their performance, durability, and competitive edge in the off-road segment.