Model:
250 EXC Racing, 450 SX, 450 MXC, 450 EXC Racing, 525 SX, 525 MXC, 525 EXC Racing
Product Type:
Engine Service Repair Manual PDF Download
Ktm Engine Codes:
Specific engine codes are not detailed in the provided product information, but are inherent to each model variant (e.g., 250cc, 450cc, 525cc for the respective model families).
Market Position:
Targeted towards KTM owners and enthusiasts looking for detailed, self-service repair and maintenance information for their 2004 EXC Racing and SX/MXC models.
Competitive Analysis:
Offers a direct and cost-effective alternative to dealership servicing, empowering users with the knowledge to perform their own repairs and maintenance.
Key Features:
Comprehensive engine repair coverage, detailed diagrams, step-by-step instructions, troubleshooting guides, electrical information, and technical specifications.
Value Proposition:
Saves money by enabling DIY repairs, provides immediate access to critical service information, and enhances user understanding of their motorcycle's mechanics.
Target Audience:
KTM owners, independent motorcycle repair shops, and DIY mechanics.
Models Covered:
2004 KTM 250 EXC RACING, 2004 KTM 450 SX, 2004 KTM 450 MXC, 2004 KTM 450 EXC RACING, 2004 KTM 525 SX, 2004 KTM 525 MXC, 2004 KTM 525 EXC RACING
Page Count:
Not explicitly stated, but implied to be comprehensive based on the listed sections.
Manual Type:
Engine Service Repair Manual
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader
Engine Systems:
Complete engine disassembly, servicing, and reassembly. Includes detailed information on individual engine components.
Repair Procedures:
Engine removal and refitting, engine disassembly, servicing of individual components, engine assembly, electrical system diagnosis and repair, troubleshooting, and periodic maintenance.
Technical Depth:
High quality diagrams and instructions suitable for DIY enthusiasts. Covers servicing and repair to a detailed level.
Troubleshooting Coverage:
Dedicated section for troubleshooting common issues.
Maintenance Coverage:
Periodic Maintenance Schedule
Electrical Coverage:
Includes electrical system servicing and wiring diagrams.
Engine Rebuild Procedures:
Complete engine disassembly, cleaning, inspection, and reassembly procedures for all internal engine components, including torque specifications for critical fasteners.
Electrical Diagnostic Procedures:
Systematic troubleshooting for starting system, charging system, ignition system, and lighting using wiring diagrams.
Technical Specifications Coverage:
Includes engine bore, stroke, compression ratio, valve timing, spark plug gap, carburetor jetting specifications, and more.
Print Quality:
High quality diagrams, printable pages
Binding Type:
Digital Download (no physical binding)
Paper Type:
N/A (Digital file)
Accessibility:
Instant download upon payment
Searchable Text:
PDF format typically allows for text search, enhancing the usability for finding specific information quickly.
Engine Displacement 250:
250cc (approximate, specific variants may vary slightly)
Engine Displacement 450:
450cc (approximate, specific variants may vary slightly)
Engine Displacement 525:
525cc (approximate, specific variants may vary slightly)
Engine Type:
Single-cylinder, four-stroke (typical for these models, specific configurations may vary)
Cooling System:
Liquid-cooled (typical for these models)
Fuel System:
Carburetor (likely Keihin or similar, specific models will be detailed in the manual)
Engine Components Covered:
Cylinder head, piston, crankshaft, connecting rod, valves, camshafts, oil pump, clutch, transmission components (within engine cases).
Transmission Type:
6-speed manual transmission (typical for these models)
Optional Transmission:
N/A (typically no factory options for transmission type on these off-road models)
Transmission Features:
Wet multi-plate clutch, gear ratios will be detailed in technical specifications.
Transmission Fluid Type:
Specific oil type and capacity for the transmission and engine clutch will be provided in the manual. Likely a high-quality motorcycle-specific 4-stroke engine oil.
Model Variants Dimensions:
Dimensions will vary between the SX (Motocross), MXC (Cross-Country), and EXC (Enduro) variants due to suspension travel, tire size, and bodywork differences. Specific dimensions are not provided but are essential for repair and maintenance.
Dry Weight:
Dry weights will vary by model (e.g., 250 EXC Racing approx. 103 kg, 450/525 models will be slightly heavier). Exact specifications are in the manual.
Safety Ratings:
Off-road motorcycles of this era do not typically undergo standardized safety crash ratings. Safety considerations will focus on proper operation, maintenance, and rider protective gear as guided by the manual.
Active Safety Features:
Effective braking system (hydraulic disc brakes front and rear), responsive suspension, and chassis stability are critical for safe operation. The manual will detail maintenance of these systems.
Passive Safety Features:
N/A (Focus is on rider protection and mechanical integrity)
Infotainment Systems:
N/A - These are performance-oriented off-road motorcycles with no infotainment features.
Driver Assistance Systems:
N/A - No electronic driver assistance systems are present on these models.
Ignition System Type:
Electronic ignition (CDI or similar) controlled by an ECU. The manual covers its servicing and troubleshooting.
Lighting System:
Includes headlight, taillight, and brake light. Wiring diagrams are provided for diagnosis.
Service Intervals:
Specific service intervals for oil changes, filter replacements, valve adjustments, and other maintenance tasks are detailed in the 'PERIODIC MAINTENANCE SCHEDULE' section of the manual.
Engine Oil Type:
The manual will specify the recommended API service classification, viscosity grade (e.g., 10W-40, 10W-50), and capacity for engine oil. Likely a premium synthetic motorcycle oil.
Coolant Type:
Recommended coolant type and mixture ratio (e.g., distilled water with ethylene glycol based antifreeze) will be specified.
Brake Fluid Type:
Likely DOT 4 or DOT 5.1 brake fluid for hydraulic brake systems.
Common Issues:
While the manual focuses on repair, general knowledge of KTMs from this era suggests potential areas for wear or maintenance include: clutch slave cylinder seals, water pump seals, carburetor jetting adjustments for altitude/temperature, and valve clearance checks. The manual's troubleshooting section will address specific problems.
Oil Filter Part Number:
Specific KTM part numbers for oil filters, air filters, and other consumables will be listed in the manual or can be cross-referenced.
Tune Up Procedures:
Includes carburetor cleaning and adjustment, spark plug replacement, air filter cleaning/replacement, and chain maintenance.
Brand Heritage:
KTM, an Austrian manufacturer, has a strong heritage in off-road motorsports, particularly motocross and enduro. The 'RACING' designation signifies performance-oriented models.
Model Evolution 2004:
The 2004 models represent a significant evolution in KTM's off-road lineup, incorporating advancements in engine technology, chassis design, and suspension for improved performance and reliability. The 450 and 525 engines, often derived from their LC4 platform, offered potent power for their respective classes.
Production Location:
KTM motorcycles are predominantly manufactured in Austria, with potential assembly in other regions.
Motorsport Success:
KTM motorcycles of this era, particularly the EXC and SX models, have a strong history of success in various off-road racing disciplines. While specific awards for the 2004 models are not detailed here, the brand's consistent performance in championships validates their engineering and capabilities.
Editorial Reviews:
Reviews from the period would have praised the power delivery, suspension performance, and handling characteristics of these KTMs. The manual aids in maintaining this performance.
Certifications:
N/A (Focus is on mechanical operation and performance)
