Target Audience:
Owners and technicians working on KTM SX, MXC, and EXC off-road motorcycles from the 2000-2003 model years.
Value Proposition:
Provides essential, in-depth technical data for maintaining and repairing these high-performance off-road machines, crucial for optimizing performance and longevity.
Manual Advantage:
Offers detailed OEM-level repair procedures, vital for accurate and efficient servicing of KTM's specialized off-road platforms.
Primary Coverage:
Comprehensive service, repair, and maintenance for KTM SX, MXC, and EXC models.
Specific Models:
250 SX, 250 MXC, 250 EXC, 400 SX, 400 MXC, 400 EXC, 450 SX, 450 MXC, 450 EXC, 520 SX, 520 MXC, 520 EXC, 525 SX, 525 MXC, 525 EXC
Estimated Page Count:
High, likely 500+ pages (typical for comprehensive WSMs of this era).
Manual Type:
Service and Repair Manual
Language:
English (presumed, standard for professional manuals)
Format:
Digital (PDF) or Printed
Engine Mechanical:
Complete engine disassembly, assembly, inspection, and repair for all specified displacements.
Engine Electrical:
Ignition system, starting system, charging system, wiring diagrams, component testing.
Fuel System:
Carburetor tuning and overhaul (likely Mikuni or Keihin variants), fuel pump, fuel lines, tank.
Transmission:
Clutch operation, gearbox disassembly, assembly, inspection, lubrication.
Suspension:
Front fork (WP USD) service, seal replacement, oil levels, damping adjustments. Rear shock absorber service, spring preload, damping.
Brakes:
Hydraulic brake system (front and rear), caliper service, master cylinder overhaul, pad replacement, fluid bleeding, rotor inspection.
Electrical System:
Lighting, battery, CDI unit, wiring diagrams, troubleshooting electrical faults.
Cooling System:
Radiator, hoses, thermostat (if applicable), coolant type and capacity.
Frame And Bodywork:
Chassis inspection, swingarm, linkages, seat, fenders, fuel tank, handlebars.
Wheels And Tires:
Wheel bearing service, spoke tensioning, tire replacement, recommended tire pressures.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, spark plug checks, air filter cleaning.
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, and mechanical problems.
Rebuilds:
Complete engine and transmission rebuild procedures with torque specifications.
Adjustments:
Valve clearance adjustment, carburetor synchronization, suspension damping adjustments.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Depth Level:
Professional-grade, in-depth coverage suitable for experienced mechanics and advanced DIY enthusiasts.
Detail Level:
Detailed step-by-step instructions, exploded views, diagrams, and specifications.
Digital Format:
PDF (searchable text and high-resolution images expected)
Print Quality:
Professional quality with clear diagrams and sharp text.
Binding Type:
Comb binding, wire-o binding, or perfect binding (for printed versions).
Paper Type:
Durable, gloss-coated paper stock suitable for workshop environments.
Engine Type:
Single-cylinder, 4-stroke (OHC, 4-valve typically for these models).
Cooling System:
Liquid-cooled (radiators).
250Cc Power Estimate:
~30-35 HP (estimated, varies by model variant)
525Cc Power Estimate:
~45-50 HP (estimated, varies by model variant)
Carburetor Type:
Mikuni TM40/TM42 or Keihin FCR (common for this era).
Fuel Type:
Unleaded gasoline (RON 95/98 recommended).
Oil Change Interval:
Typically every 10-15 hours of riding or annually, whichever comes first. (Consult manual for exact interval based on usage).
Air Filter Cleaning:
Frequent cleaning required, ideally after every few rides, especially in dusty conditions.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment; check for wear.
Engine Oil Type:
High-quality motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 or 10W-50 (specific viscosity and API rating required, consult manual).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (50% mixture with distilled water recommended).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Piston rings, valve guides, cam chain, clutch plates, wheel bearings, suspension seals.
Carburetor Tuning:
Can require frequent adjustment based on altitude, temperature, and modifications.
Electrical Connections:
Corrosion or looseness in connectors can lead to intermittent electrical faults.
Ktm Offroad Focus:
KTM has a long-standing heritage in off-road motorsports, with a strong reputation for performance and durability in motocross, enduro, and rally racing.
Sx Mxc Exc Series:
These series represent KTM's core off-road offerings: SX for Motocross, EXC for Enduro, and MXC as a hybrid or earlier enduro designation. This period saw significant development in their 4-stroke engine technology.
Manufacturing Origin:
Austria (KTM AG).
