HAYNES Service and Repair Manual
KTM EXC Enduros & SX Motocross sohc 4-strokes
2000 to 2007
250 EXC 249cc 2002-06
400 EXC 398cc 2000-07
450 EXC 448cc 2003-07
520/525 EXC 510cc 2000-07
400 MXC 398cc 2001-02
450 MXC 448cc 2003-06
520/525 MXC/XC 510cc 2001-07
400 SX 398cc 2000-02
450 SX 449cc 2003-06
520/525 SX 510cc 2000-06
Covers main features of SMR supermoto
**Does not include dohc EXC-F & SX-F
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Description
Step-by-step instructions clearly linked to hundreds of photos and illustrations show you how to do each job. Spanner ratings grade all tasks by difficulty and experience level. Haynes Hints give valuable tips and short-cuts that help make the job easier.
Inside this Manual:
- Model history and Pre-ride Checks in colour
- A complete step-by-step guide to servicing and routine maintenance
- Engine and transmission — servicing and overhaul
- Braking system — safety checks and repairs
- Fuel and ignition systems explained
- Electrical system — troubleshooting and repairs
- Comprehensive colour wiring diagrams
- 18 page Tools & Workshop Tips section in colour
- Troubleshooting checklist and equipment to pinpoint specific problems.
- Suspension and steering — adjustment and overhaul
- Fully indexed to help you find information easily
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Table of Contents
Introduction
- The Birth of a Dream
- Acknowledgements
- About this manual
- Identification numbers
- Buying spare parts
- Model Development
- Safety first!
- Bike Spec
- Daily (pre-ride) checks
- Engine/Transmission Oil level check
- Suspension, steering and drive chain checks
- Legal and safety checks
- Disc Brake fluid level checks
- Drum Brake Checks
- Tyre checks
- Coolant Level Checks
- MAINTENANCE
- Routine maintenance and servicing
- Specifications
- Recommended lubricants and fluids
- Component locations
- Maintenance schedule
- Maintenance procedures
- REPAIRS AND OVERHAUL
- Engine, transmission and associated systems
- Engine
- Clutch and transmission
- Cooling System
- Fuel and exhaust systems
- Ignition system
- Chassis and bodywork components
- Suspension
- Final drive
- Brakes
- Wheels
- Tyres
- Frame
- Fairing and Bodywork
- Electrical system
- Wiring diagrams
- REFERENCE
- Tools and Workshop Tips
- Security
- Lubricants and Fluids
- Conversion Factors
- MOT Test Checks
- Storage
- Troubleshooting
- Troubleshooting equipment
- Technical terms explained
o Tool Tips contain useful information such as ways of removing parts without using special tools. This Haynes Manual was written from hands-on experience, based on the stripdown and rebuild using commonly - available tools. From easy servicing jobs for the novice to difficult tasks for the expert.
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