2000-2005 KTM 250-525 EXC SX MXC Racing Motorcycle Service Manual

This manual provides comprehensive repair instructions and up-to-date information for the latest models in the series, covering all working modes and safety rules.

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Document Details

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Document Number / Seller:
30447 / Amanda Harris
File Size:
22.61 MB
File Type:
PDF
Language:
English
Pages:
410
Printable:
Yes
Category:
Motorbike
Last updated / verified
Dec 30, 2025

Models Covered & Key Technical Specifications

2000-2005 KTM 250-525 EXC/SX/MXC/SMR/SXS Racing Motorcycle Service & Repair Manual

This manual provides comprehensive repair instructions and up-to-date information for the latest models in the series, covering all working modes and safety rules. | Official KTM Factory Service & Repair Manual Package

  • System Diagnostics: 410 pages of detailed diagnostic procedures ensures comprehensive troubleshooting coverage.
  • Engine Specifications: Full synthetic engine oil (Motorex Power Synt 4T 10W/50) is recommended for optimal engine performance.
  • Chassis Adjustments: Fork and shock absorber adjustments can be made with compression adjusters ranging from 14 to 22 clicks.
  • Brake System Details: Brake discs have a wear limit of 2.5 mm front and 3.5 mm rear for safety.
  • Tire Pressure Recommendations: Off-road tires require 1.0 bar (14 psi) for optimal grip.
  • Fuel Tank Capacity: The fuel tank capacity is 7.5 liters (2 US gallons) for extended range.

Professional Workshop Service Manual & Technical Specifications

KTM 250-525 EXC/SX/MXC/SMR/SXS Racing Factory Service & Repair Manual 2000-2005

Diagnostic-Area: 410 pages // Repair-Classification: Comprehensive Guide / Motorcycle Logic // Application-Range: All Years and Models Covered.

Assessment-Element Technical-Path Framework
Engine Model KTM 250-525 EXC/SX/MXC/SMR/SXS 2000-2005 Models
Manual Type Factory Service & Repair Digital Document
Key Systems Covered Engine, Chassis, Electrical, Fuel, Troubleshooting Included Diagrams and Schematics
Maintenance Schedule Periodic Maintenance Overview Recommended Intervals Specified
Key Specifications Bore/Stroke, Gear Ratios, Tire Pressures Detailed Technical Data Enclosed

Reference chapters include: Engine Specifications, Chassis Technical Data, Carburetor Settings, Electrical System, Fuel System, Troubleshooting, and Wiring Diagrams.

Consistently requiring expert knowledge, this manual outlines procedures for engine, chassis, and electrical system maintenance. It details various specifications, including engine oil requirements and tire pressure recommendations, to ensure your KTM performs at its peak. Torque specifications for various components are documented to ensure proper seal compression uniformity.

This manual covers a wide range of procedures, from basic maintenance to complex repairs, ensuring you have all the information needed to keep your KTM running smoothly. It details how to address issues within the fuel system, electrical system, and engine, providing clear instructions for each step.

FAQ

What are the **precise** pressure specifications for the tires? keyboard_arrow_down

For off-road use, front and rear tires require 1.0 bar (14 psi). Road-driven tires require 1.5 bar (21 psi) for the front and 2.0 bar (28 psi) for the rear.

What is the **proper** assembly sequence for the clutch? keyboard_arrow_down

Clutch disks up to the 2001 model: Start with an intermediate disc, then alternate between 8 intermediate discs and 7 lining discs, with an intermediate disc on top. From the 2002 model onwards: Use 12 driving pin sleeves, start with a thin clutch disk, alternate 8 clutch disks and 6 lining disks, finishing with a thin clutch disk on top.

What are the **standard** service interval parameters? keyboard_arrow_down

For competition use, a 15-hour service should be carried out after every race. Service intervals should never be exceeded by more than 2 hours or 15 liters of fuel.

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Reviews (5)

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I found this manual incredibly detailed and helpful. It made my maintenance tasks much easier. Excellent download process too!
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I had a question after my purchase, and their support responded within hours! The manual itself is fantastic as well.
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This manual is a lifesaver! The instructions are clear and easy to follow. Highly recommend it to any KTM owner!
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Rated 4 out of 5 stars
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The download link came through immediately after purchase. The manual is detailed and very useful for my repairs!