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KTM 250EXC 450SX MXC EXC 525SX MXC EXC owners Manual.2004

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🏷️ Basic Information Identification Make: KTM Model: 250 EXC, 450 SX, 450 MXC, 450 EXC, 525 SX, 525 MXC, 525 EXC Year: 2004 Codes Platform Code: Varies by specific model...
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Type: Motorcycle
Vendor:
Ktm
Sku: 71958
Tags: 2004 250EXC 450 450SX 525SX KTM Motorcycle Motorcycles MXC EXC
KTM 250EXC 450SX MXC EXC 525SX MXC EXC owners Manual.2004
🏷️ Basic Information
Identification
Make:
KTM
Model:
250 EXC, 450 SX, 450 MXC, 450 EXC, 525 SX, 525 MXC, 525 EXC
Year:
2004
Codes
Platform Code:
Varies by specific model variant (e.g., EXC platform, SX platform)
Engine Code 250:
Likely LC4 or similar single-cylinder designation for EXC models
Engine Code 450 525:
Likely LC4 V-twin or large single-cylinder designation for SX/MXC/EXC models
👋 Introduction
Market Position
Vehicle Class:
High-performance off-road motorcycles (Enduro, Motocross, Supermoto variants).
Target Audience:
Enthusiast riders focused on off-road competition, trail riding, and extreme sports.
Competitive Analysis
Key Competitors:
Yamaha WR series, Honda CR-FX series, Suzuki RMX series, Husqvarna TE series.
Key Features
Kتم Brand Philosophy:
Ready to Race - focus on performance, lightweight design, and robust components.
Model Variations:
The manual covers a range of displacements and intended uses (EXC for Enduro, SX/MXC for Motocross/Cross-Country).
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive owner's manual covering operation, maintenance, and basic adjustments for multiple 2004 KTM models.
Page Count
Estimated Page Count:
Approximately 150-250 pages (estimated for comprehensive owner's manuals of this era).
Manual Type
Manual Type:
Owner's Manual
Language
Language:
English (assumed, typical for international sales)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Cooling system, lubrication system, fuel system (carburetor), ignition system, starting system.
Transmission Drivetrain:
Clutch operation, gearbox function, final drive chain maintenance.
Chassis Suspension:
Front fork operation and basic adjustments, rear shock absorber operation, frame, swingarm, and linkage maintenance.
Brakes:
Hydraulic brake system operation (front and rear), brake fluid checks and replacement procedures.
Electrical:
Lighting system, battery maintenance, basic electrical component identification.
Controls Instruments:
Handlebar controls, dashboard indicators, instrument cluster functions.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air), spark plug inspection, chain adjustment, lubrication points.
Inspections Adjustments:
Pre-ride checks, brake lever and pedal adjustments, clutch lever adjustment, suspension sag adjustment (basic).
Troubleshooting:
Basic troubleshooting guides for common operational issues.
Safety Information:
Safe riding practices, protective gear recommendations, general warning notices.
Technical Depth
Depth Of Coverage:
Owner-level maintenance and basic operational guidance. Does not include detailed engine teardown or complex electronic diagnostics.
📊 Manual Specifications
File Format
File Format Type:
PDF (Portable Document Format)
Searchability:
Typically searchable text within PDF format, allowing for quick information retrieval.
Print Quality
Print Quality Recommendation:
High resolution for clear diagrams and text, suitable for printing.
Binding Type
Binding Type If Printed:
Not applicable (digital format), but original manuals were typically saddle-stitched or perfect bound.
Paper Type
Paper Type If Printed:
Not applicable (digital format), but original manuals often used durable, gloss paper.
⚙️ Engine Specifications
Primary Engine 250
Engine Type 250:
Likely a 249cc (approx.) single-cylinder, four-stroke engine.
Primary Engine 450 525
Engine Type 450 525:
Likely a 449cc (for 450 models) or 510cc (for 525 models) single-cylinder, four-stroke engine (LC4 platform).
Performance 250
Horsepower 250 Estimated:
Approximately 30-40 HP (estimated, specific output varies by tuning and model).
Performance 450 525
Horsepower 450 Estimated:
Approximately 45-55 HP (estimated, specific output varies by tuning and model).
Horsepower 525 Estimated:
Approximately 50-60 HP (estimated, specific output varies by tuning and model).
Fuel System
Fuel Delivery:
Carburetor (e.g., Keihin FCR series).
Fuel Type:
Unleaded gasoline (RON 91 or higher).
Cooling System
Cooling Method:
Liquid-cooled.
Lubrication
Oil Type:
High-quality motorcycle specific 4-stroke engine oil (e.g., SAE 10W-40 or 10W-50, JASO MA rated).
Oil Capacity 250
Oil Capacity Engine 250:
Approximately 1.0 - 1.2 liters (check manual for exact specification).
Oil Capacity 450 525
Oil Capacity Engine 450 525:
Approximately 1.2 - 1.5 liters (check manual for exact specification).
Spark Plug
Spark Plug Type:
NGK (e.g., CR9E, CR10E) or equivalent, specific type to be confirmed in manual.
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission.
Optional
Optional Gearbox:
Not applicable (standard 6-speed).
Features
Clutch Type:
Hydraulic actuated, multi-plate wet clutch.
Gearbox Oil Type:
Separate gearbox oil may be specified, or shared with engine oil depending on exact design (check manual).
📐 Dimensions
Exterior 250Exc
Seat Height 250Exc Approx:
Approximately 950-960 mm (37.4-37.8 inches).
Exterior 450 525
Seat Height 450 525 Approx:
Approximately 960-970 mm (37.8-38.2 inches).
Weights 250Exc
Dry Weight 250Exc Approx:
Approximately 105-110 kg (231-242 lbs).
Weights 450 525
Dry Weight 450 525 Approx:
Approximately 110-120 kg (242-265 lbs).
Fuel Capacity
Fuel Tank Capacity Approx:
Approximately 7.5 - 9.5 liters (1.9 - 2.5 gallons), depending on model variant.
Wheels Tires
Front Wheel Size:
21 inches.
Rear Wheel Size:
18 inches.
Front Tire Size Spec:
Commonly 80/100-21, specific DOT rating recommended.
Rear Tire Size Spec:
Commonly 100/90-18 or 110/100-18, specific DOT rating recommended.
🛡️ Safety Features
Ratings
Safety Rating Classification:
N/A (Off-road motorcycles are not typically subject to automotive safety ratings like NHTSA or Euro NCAP).
Active Features
Braking System:
Hydraulic disc brakes front and rear (Brembo components often used).
Suspension Features:
Adjustable front forks (compression/rebound) and rear shock absorber (preload/rebound), contributing to stability and control.
Passive Features
Frame Design:
Chromoly steel trellis frame for strength and light weight.
Handguards:
Standard or optional handguards to protect levers and rider's hands.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic instrument cluster only).
Driver Assistance
Electronic Aids:
N/A (No electronic rider aids like ABS or traction control on these models).
Connectivity
Connectivity Features:
N/A.
Instrumentation
Dashboard Features:
Speedometer, odometer, trip meter, neutral indicator, turn signal indicators, high beam indicator, engine warning light.
🔧 Maintenance
Service Intervals Oil
Engine Oil Change Interval:
Every 15-30 operating hours or annually (highly dependent on usage conditions, refer to manual).
Service Intervals Air Filter
Air Filter Cleaning Interval:
Every 5-10 operating hours or as needed, especially in dusty conditions.
Service Intervals Spark Plug
Spark Plug Inspection Interval:
Every 15-30 operating hours.
Service Intervals Chain
Chain Lubrication Adjustment Interval:
Every ride or as needed, check tension frequently.
Fluid Specifications
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Coolant Type:
Ethylene glycol based antifreeze coolant (e.g., Motorex Coolant M5.0).
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, chain and sprockets, fork seals, swingarm bushings.
Engine Specific Considerations:
Regular valve clearance checks are crucial for LC4 engines. Overheating can occur if cooling system is not maintained.
Electrical Considerations:
While generally robust, ensure battery terminals are clean and connections are secure. Charging system should be checked if battery issues arise.
📚 Vehicle History
Brand Heritage
Kتم Motorsports Legacy:
KTM has a long and successful history in off-road racing, including motocross, enduro, and rally raids, influencing the development of these models.
Model Evolution
Lc4 Platform Significance:
The LC4 engine platform, prevalent in the 450/525 models, is known for its torque and durability in demanding off-road conditions.
Production
Ktm Manufacturing Origin:
Austria.
🏆 Awards & Recognition
Recognitions
Kتم Offroad Dominance:
KTM is consistently recognized for its success in off-road racing championships, a testament to the performance capabilities of their models.
Ratings
Media Reviews 2004:
KTM off-road models from this era generally received praise for their powerful engines, advanced suspension, and competitive chassis.
Certifications
Emissions Compliance:
Compliance with relevant emissions standards for off-road vehicles in the target markets of 2004.
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