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2000-2003 KTM 250, 400, 450, 520, 525, SX, MXC, EXC, Racing engine repair manual Preview image 1
2000-2003 KTM 250, 400, 450, 520, 525, SX, MXC, EXC, Racing engine repair manual Preview image 2
2000-2003 KTM 250, 400, 450, 520, 525, SX, MXC, EXC, Racing engine repair manual Preview image 3
2000-2003 KTM 250, 400, 450, 520, 525, SX, MXC, EXC, Racing engine repair manual Preview image 4
2000-2003 KTM 250, 400, 450, 520, 525, SX, MXC, EXC, Racing engine repair manual Preview image 5
2000-2003 KTM 250, 400, 450, 520, 525, SX, MXC, EXC, Racing engine repair manual Preview image 6

2000-2003 KTM 250, 400, 450, 520, 525, SX, MXC, EXC, Racing engine repair manual

Includes the following models

  • 2000 KTM 250 SX/MXC/EXC/Racing
  • 2000 KTM 400 SX/MXC/EXC/Racing
  • 2000 KTM 450 SX/MXC/EXC/Racing
  • 2000 KTM 520 SX/MXC/EXC/Racing
  • 2000 KTM 525 SX/MXC/EXC/Racing
  • 2001 KTM 250 SX/MXC/EXC/Racing
  • 2001 KTM 400 SX/MXC/EXC/Racing
  • 2001 KTM 450 SX/MXC/EXC/Racing
  • 2001 KTM 520 SX/MXC/EXC/Racing
  • 2001 KTM 525 SX/MXC/EXC/Racing
  • 2002 KTM 250 SX/MXC/EXC/Racing
  • 2002 KTM 400 SX/MXC/EXC/Racing
  • 2002 KTM 450 SX/MXC/EXC/Racing
  • 2002 KTM 520 SX/MXC/EXC/Racing
  • 2002 KTM 525 SX/MXC/EXC/Racing
  • 2003 KTM 250 SX/MXC/EXC/Racing
  • 2003 KTM 400 SX/MXC/EXC/Racing
  • 2003 KTM 450 SX/MXC/EXC/Racing
  • 2003 KTM 520 SX/MXC/EXC/Racing
  • 2003 KTM 525 SX/MXC/EXC/Racing

Production/model years: 2000, 2001, 2002, 2003

File specifications

File size: 26.36 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.54 Minutes
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Product Information

Table of Contents

1. Service-Informations

  • Introduction
  • Safety Precautions
  • Tools and Equipment

2. General Information

  • Engine Overview
  • Specifications
  • Torque Settings

3. Removing and Refitting Engine

  • Preparation
  • Engine Removal Procedure
  • Engine Installation Procedure

4. Disassembling Engine

  • Preliminary Steps
  • Cylinder Head Removal
  • Crankcase Separation

5. Servicing Individual Components

  • Cylinder Head Service
  • Valve Inspection and Service
  • Piston and Cylinder Service
  • Crankshaft Service

6. Assembling Engine

  • Preliminary Steps
  • Crankcase Assembly
  • Cylinder Head Installation
  • Final Assembly Checks

7. Electrical

  • Electrical Components Overview
  • Ignition System
  • Charging System
  • Troubleshooting Electrical Issues

8. Fuel System

  • Fuel System Overview
  • Carburetor Service
  • Fuel Pump and Filter Service
  • Troubleshooting Fuel System

9. Technical Specifications

  • Engine Specifications
  • Performance Data
  • Emission Data

10. Periodic Maintenance Schedule

  • Maintenance Intervals
  • Maintenance Tasks
  • Lubrication and Fluids

11. Wiring Diagrams

  • Engine Wiring Diagram
  • Electrical System Wiring Diagram

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Manuals frequently bought together

2000-2007 KTM 250 EXC RACING, 400/450 SX,MXC,XC,XC-W,EXC,SMR,SXS RACING, 520/525 SX,MXC,XC,XC-W,EXC,SMR RACING, 540 SXS, 560 SMR, 610 CRATE engine manual

  • 2000-2007 KTM 250 EXC RACING
  • 2000-2007 KTM 400/450 SX,MXC,XC,XC-W,EXC,SMR,SXS RACING
  • 2000-2007 KTM 520/525 SX,MXC,XC,XC-W,EXC,SMR RACING
  • 2000-2007 KTM 540 SXS, 560

2000-2007 KTM 250, 400, 450, 520, 525, 540, 610 repair manual

KTM Sportmotorcycle AG

  • KTM 250 EXC 2000-2007
  • KTM 400 450 SX MXC XC XC-W EXC SMR SXS 2000-2007
  • KTM 520 525 SX MXC XC XC-W EXC SMR 2000-2007
2008 Polaris Outlaw 450 MXR, 525 S, 525 IRS ATV service manual

450 MXR, 525 S, 525 IRS / Polaris Industries

Production/model years: 2008

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