This manual covers the 2004 250 EXC, 450 SX, 450 MXC, 450 EXC, 525 SX, 525 MXC, and 525 EXC models. These high-performance off-road motorcycles are engineered with a "Ready to Race" philosophy, emphasizing lightweight design, robust components, and powerful engines, often utilizing the renowned LC4 platform. Known for their success in motorsports, these bikes are built for enthusiast riders engaged in motocross, enduro, and cross-country riding, offering a competitive edge through advanced suspension and strong chassis designs.
This comprehensive owner's manual provides essential guidance for operating, maintaining, and performing basic adjustments on your 2004 motorcycle. It details coverage of key systems including the engine, transmission, chassis, brakes, and electrical components. Within its approximately 150-250 pages, you will find information on routine maintenance procedures, inspections, adjustments, basic troubleshooting, and important safety guidelines. This manual serves as a vital resource for owners and technicians to ensure the optimal performance and longevity of the vehicle.
Model:
250 EXC, 450 SX, 450 MXC, 450 EXC, 525 SX, 525 MXC, 525 EXC
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
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.
Key Competitors:
Yamaha WR series, Honda CR-FX series, Suzuki RMX series, Husqvarna TE series.
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 Coverage Scope:
Comprehensive owner's manual covering operation, maintenance, and basic adjustments for multiple 2004 KTM models.
Estimated Page Count:
Approximately 150-250 pages (estimated for comprehensive owner's manuals of this era).
Manual Type:
Owner's Manual
Language:
English (assumed, typical for international sales)
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.
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.
Depth Of Coverage:
Owner-level maintenance and basic operational guidance. Does not include detailed engine teardown or complex electronic diagnostics.
File Format Type:
PDF (Portable Document Format)
Searchability:
Typically searchable text within PDF format, allowing for quick information retrieval.
Print Quality Recommendation:
High resolution for clear diagrams and text, suitable for printing.
Binding Type If Printed:
Not applicable (digital format), but original manuals were typically saddle-stitched or perfect bound.
Paper Type If Printed:
Not applicable (digital format), but original manuals often used durable, gloss paper.
Engine Type 250:
Likely a 249cc (approx.) single-cylinder, four-stroke engine.
Engine Type 450 525:
Likely a 449cc (for 450 models) or 510cc (for 525 models) single-cylinder, four-stroke engine (LC4 platform).
Horsepower 250 Estimated:
Approximately 30-40 HP (estimated, specific output varies by tuning and model).
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 Delivery:
Carburetor (e.g., Keihin FCR series).
Fuel Type:
Unleaded gasoline (RON 91 or higher).
Cooling Method:
Liquid-cooled.
Oil Type:
High-quality motorcycle specific 4-stroke engine oil (e.g., SAE 10W-40 or 10W-50, JASO MA rated).
Oil Capacity Engine 250:
Approximately 1.0 - 1.2 liters (check manual for exact specification).
Oil Capacity Engine 450 525:
Approximately 1.2 - 1.5 liters (check manual for exact specification).
Spark Plug Type:
NGK (e.g., CR9E, CR10E) or equivalent, specific type to be confirmed in manual.
Transmission Type:
6-speed manual transmission.
Optional Gearbox:
Not applicable (standard 6-speed).
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).
Seat Height 250Exc Approx:
Approximately 950-960 mm (37.4-37.8 inches).
Seat Height 450 525 Approx:
Approximately 960-970 mm (37.8-38.2 inches).
Dry Weight 250Exc Approx:
Approximately 105-110 kg (231-242 lbs).
Dry Weight 450 525 Approx:
Approximately 110-120 kg (242-265 lbs).
Fuel Tank Capacity Approx:
Approximately 7.5 - 9.5 liters (1.9 - 2.5 gallons), depending on model variant.
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 Rating Classification:
N/A (Off-road motorcycles are not typically subject to automotive safety ratings like NHTSA or Euro NCAP).
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.
Frame Design:
Chromoly steel trellis frame for strength and light weight.
Handguards:
Standard or optional handguards to protect levers and rider's hands.
Infotainment System:
N/A (Basic instrument cluster only).
Electronic Aids:
N/A (No electronic rider aids like ABS or traction control on these models).
Connectivity Features:
N/A.
Dashboard Features:
Speedometer, odometer, trip meter, neutral indicator, turn signal indicators, high beam indicator, engine warning light.
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.
Chain Lubrication Adjustment Interval:
Every ride or as needed, check tension frequently.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Coolant Type:
Ethylene glycol based antifreeze coolant (e.g., Motorex Coolant M5.0).
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.
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.
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.
Ktm Manufacturing Origin:
Austria.
Kتم Offroad Dominance:
KTM is consistently recognized for its success in off-road racing championships, a testament to the performance capabilities of their models.
Media Reviews 2004:
KTM off-road models from this era generally received praise for their powerful engines, advanced suspension, and competitive chassis.
Emissions Compliance:
Compliance with relevant emissions standards for off-road vehicles in the target markets of 2004.
