KTM 250 400 450 520 525 SX MXC EXC 2000-2003 Service Manual

250-525 SX, MXC, EXC RACING REPAIR MANUAL ENGINE KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria www.ktm.at

REPAIR MANUAL ENGINE 250-525 SX, MXC, EXC RACING

1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING ENGINE 5 SERVICING INDIVIDUAL COMPONENTS 6 ASSEMBLING ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TECHNICAL SPECIFICATIONS 10 PERIODIC MAINTENANCE SCHEDULE 11 WIRING DIAGRAMS 12 13 14 15 16

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E I MPORTANT I NFORMATION /U PDATING INSTRUCTIONS To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions: 14, 21-24, 30-47, 50-52, 56-76, 79-92, 97-124, 134-140, 142, 150-154, 165-167 KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder. – Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder. – Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. – Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3“. – Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents. Remove page (s) Replace by page (s) Insert page (s) after page 2-1 / 2-7 2-1C 2-7C to 2-9C 3-1 3-1C 4-1 to 4-14 4-1C to 4-13C 5-1 / 5-3 5-1C / 5-3C 5-6 to 5-8 5-6C to 5-8C 5-12 to 5-26 5-12C to 5-27C 6-1 / 6-4 6-1C / 6-4C 6-7 to 6-16 6-7C to 6-17C 7-1 to 7-2 7-1C to 7-2C 7-7 to 7-11 7-7C to 7-11C 8-1 to 8-13 8-1C to 8-21C 9-1 9-1C 9-10 to 9-13 9-10C to 9-16C 10-1 10-1C 10-8C to 10-11C 11-1 11-1C 11-11C to 11-13C

Repair manual KTM 250-525 SX, MXC, EXC RACING Art.-No. 3206007 -E E XPLANATION - U PDATING Edition 01/2003 3.205.85-E Repair Manual 400/520 SX, MXC, EXC RACING Basic version Model year 2000 (Engine number with first digit “0“) 2/2000 3.210.01-E Updating of Rep.Manual 3.205.85-E Model year 2001 (Engine number with first digit “1“) 1/2001 3.210.44-E Updating of Rep.Manual 3.205.85-E Model year 2002 (Engine number with first digit “2“) 2/2002 3.206.007-E Updating of Rep.Manual 3.205.85-E Model year 2003 (Engine number with first digit “3“) 1/2003 Modification / Updating: Technical Details Model 2003 (clutch, valve spring, camshaft gear, carburetor) Technical Specifications, Periodic Maintenance Schedule, Wiring Diagrams

KTM 250 400 450 520 525 SX MXC EXC 2000-2003 Service Manual

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