Model:
250 EXC, 450 SX, 450 EXC, 525 SX, 525 EXC
Product Type:
Owner's Manual
Manual Identifier:
Likely contains specific part numbers for the manual itself, e.g., 3206127en or similar for the 250EXC, 3206128en for the 450/525 models, though not explicitly stated in product info.
Category:
High-performance off-road motorcycles (Enduro and Motocross).
Target Audience:
Enthusiast riders engaged in off-road riding, trail riding, and competitive motocross/enduro events.
Competitors 2003:
Yamaha WR series, Honda CR-FX series, Suzuki RM-X series, Husqvarna TE/CR models.
Ktm Philosophy:
Known for 'Ready to Race' philosophy, emphasizing performance, handling, and advanced componentry for their era.
Model Focus:
The EXC variants are geared towards enduro (timed stages, off-road legality in some regions), while the SX variants are pure motocross machines.
Primary Coverage:
Operation, maintenance, basic adjustments, safety, and rider information for KTM 250 EXC, 450 SX, 450 EXC, 525 SX, and 525 EXC models.
Secondary Coverage:
Visual identification of components, basic care instructions, and understanding of dashboard indicators.
Estimated Pages:
Estimated 50-100 pages based on typical KTM owner's manuals for this era and complexity, but specific count not provided.
Language:
English (indicated by 'owners Manual' and likely standard for imported models, though other languages may exist).
Engine Operation:
Starting procedures, engine break-in, operation limits, cooling system overview (liquid cooling).
Chassis Components:
Suspension (fork and rear shock), brakes (hydraulic), wheels, tires, steering.
Controls And Instruments:
Handlebar controls, dashboard layout, warning lights, instrumentation functions.
Fuel And Lubrication:
Fuel type recommendations, oil specifications and change intervals, coolant specifications.
Electrical System:
Battery maintenance (basic), fuse identification (likely), lighting operation.
Daily Checks:
Pre-ride inspection checklist: tires, brakes, fluid levels, controls.
Maintenance Tasks:
Chain adjustment, air filter cleaning/replacement, spark plug inspection, oil and filter changes (basic guidance).
Adjustments:
Clutch and throttle cable free play adjustment, brake lever adjustment (if applicable).
Troubleshooting:
Basic troubleshooting guidance for common operational issues (e.g., starting problems, unusual noises).
Depth:
Owner-level maintenance and operation. Focuses on what the rider can and should do. Does not typically include in-depth engine disassembly, transmission rebuilds, or complex electrical diagnostics.
Engine Type 250:
4-stroke, single-cylinder, OHC (Overhead Camshaft), liquid-cooled.
Engine Type 450 525:
4-stroke, single-cylinder, OHC (Overhead Camshaft), liquid-cooled. Likely shares bore/stroke variations on a common platform.
Bore Stroke 250:
Typical for this era might be around 76mm bore x 54.8mm stroke for a 250cc.
Bore Stroke 450:
Typical for this era might be around 95mm bore x 63.4mm stroke for a 450cc.
Bore Stroke 525:
Typical for this era might be around 95mm bore x 72mm stroke for a 525cc.
Horsepower 250:
Estimated 35-40 HP (stock, at crankshaft). Exact figures would be in service manual.
Horsepower 450:
Estimated 45-50 HP (stock, at crankshaft).
Horsepower 525:
Estimated 50-55 HP (stock, at crankshaft).
Carburetor:
Likely Keihin FCR series flat-slide carburetors (e.g., FCR 39 or 41mm), known for performance and throttle response.
Fuel Type:
Unleaded gasoline, minimum Octane Rating 91 (RON+MON)/2 (AKI). Check manual for specific octane requirement.
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with variable ignition timing.
Type:
6-speed constant mesh gearbox.
Optional Gearing:
Not typically offered as an option from the factory, but aftermarket gearing is common.
Clutch Type:
Hydraulically actuated multi-disc wet clutch.
Transmission Oil Spec:
Refer to manual for specific grade. Likely a high-quality motorcycle-specific transmission oil, e.g., SAE 10W-40 or 15W-50, meeting JASO MA standards.
Wheelbase Approx:
Approximately 1470-1480 mm (57.9-58.3 inches), varies slightly by model.
Seat Height Approx:
Approximately 950-970 mm (37.4-38.2 inches), typical for performance off-road bikes.
Dry Weight Approx 250:
Around 105-110 kg (231-243 lbs) dry.
Dry Weight Approx 450 525:
Around 110-115 kg (243-254 lbs) dry.
Fuel Capacity:
Typically 7.5 - 9.5 liters (approx. 2.0 - 2.5 US gallons), including reserve. Check manual for exact figure.
Safety Certification:
N/A (Off-road competition vehicles are not typically subject to DOT or NHTSA safety ratings in the same way as street vehicles).
Brakes Front:
Hydraulic disc brakes with dual-piston calipers (e.g., Brembo). Rotor size likely 260mm.
Brakes Rear:
Hydraulic disc brakes with single-piston calipers (e.g., Brembo). Rotor size likely 220mm.
Suspension Front:
Upside-down telescopic forks (e.g., WP Suspension), with adjustable compression and rebound damping. Likely 48mm stanchion diameter.
Suspension Rear:
Monoshock linkage system (PDS - Progressive Damping System or similar), with adjustable preload, compression, and rebound damping.
Handguards:
Standard on most KTM off-road models to protect levers and hands.
Engine Guard:
Often fitted as standard or a common dealer/aftermarket upgrade to protect the engine cases.
Oil Change Interval:
Typically every 10-15 hours of riding or annually. Consult manual for precise figure.
Air Filter Cleaning:
Recommended after every few rides, or more frequently in dusty conditions.
Spark Plug Inspection:
Typically around 20-30 hours of riding. Check manual for specific plug type and gap.
Engine Oil Capacity:
Approximately 1.5 - 1.8 liters. Precise capacity and type (e.g., SAE 10W-40, API SG or higher, JASO MA) must be verified in the manual.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Refer to manual for specific KTM coolant recommendation or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid. Use only fresh fluid from a sealed container.
Clutch Slave Cylinder Seal:
Some KTM models of this era could be prone to seal leakage in the hydraulic clutch slave cylinder, requiring replacement.
Carburetor Jetting:
Keihin FCR carbs are generally robust, but performance can be optimized with jetting changes depending on altitude and temperature, which this manual might touch upon in operation.
Suspension Seals:
As with any performance off-road bike, regular maintenance of fork and shock seals is crucial to prevent leaks and maintain performance.
Ktm Offroad Legacy:
KTM has a long and successful history in off-road motorsports, particularly in enduro and motocross, dating back to the 1950s.
2003 Generation:
This generation represents a significant evolution for KTM's four-stroke off-road bikes, building on previous LC4 and smaller displacement platforms. Introduced significant chassis and engine refinements.
Sx Vs Exc:
SX models are dedicated motocross bikes optimized for track use. EXC models are enduro-focused, often with slightly different suspension settings, gear ratios, and sometimes provisions for lights/off-road legality (though many 2003 models were race-prepped).
Manufacturing Location:
Austria (KTM Sportmotorcycle AG, Mattighofen).
