🏷️ Basic Information Identification Make: KTM Model: 450 EXC / 400 EXC / 520 SX Product Name: KTM 450 EXC 400 EXC 520 SX 2000-2003 Factory Repair Manual PDF Download Codes Product Code: KTM-2000-2003-EXC-SX-RM-PDF 👋 Introduction Market Position Target Audience: KTM owners, mechanics, and enthusiasts seeking to maintain and repair their 2000-2003 450 EXC, 400 EXC, and 520 SX models. Value Proposition: Provides factory-level expertise, enabling DIY maintenance and repairs, saving significant labor costs. Competitive Analysis Authenticity: Actual Genuine Repair Service Factory Manuals, not third-party alternatives. Key Features Comprehensiveness: Covers all aspects of maintenance, repair, and diagnostics for the specified models. Usability: Easy to navigate, print, and follow, even for those not highly computer-skilled. Cost Savings: Potential to save $50-$60 per hour on shop labor costs. 📋 Manual Details Coverage Areas Covered Years: 2000, 2001, 2002, 2003 Covered Models: 450 EXC, 400 EXC, 520 SX Page Count Estimated Pages: Hundreds of pages (specific number not provided, but implied extensive) Manual Type Type: Official Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Top End: Detailed procedures for cylinder head, valves, piston, rings, camshafts. Fuel System: Carburetor settings, fuel pump, fuel lines, fuel tank inspection and repair. Cooling System: Radiator, coolant hoses, water pump, thermostat, coolant specifications. Clutch: Clutch lever, cable adjustment, clutch plates, springs, pressure plates, clutch cover. Engine Lubrication System: Oil pump, oil filter, oil passages, oil level checks, oil type specifications. Engine Removal Installation: Step-by-step procedure for removing and reinstalling the engine assembly. Crankshaft Transmission: Crankshaft inspection, connecting rod, gearbox, gear shifting mechanisms, transmission bearings. Wheels Tires: Wheel bearing inspection, spoke tensioning, tire pressure recommendations, tire replacement. Final Drive: Chain maintenance, sprocket inspection, rear hub assembly. Brakes: Brake lever, pedal, brake calipers, master cylinders, brake fluid specifications, brake pad replacement, disc inspection. Suspension: Front fork (USD), rear shock absorber, suspension settings, seal replacement, oil levels. Steering: Handlebar, steering stem, steering head bearings, adjustment procedures. Frame: Frame inspection, welds, potential damage assessment. Electrical System: Ignition system, lighting, battery, wiring diagrams, troubleshooting electrical faults. General Information: Vehicle identification, torque specifications, maintenance overview, safety precautions. Appendix: Supplementary technical data, specifications, and charts. Procedures Included Maintenance: Routine checks, lubrication, fluid changes, filter replacements, cable adjustments. Troubleshooting: Diagnostic guides for engine faults, electrical issues, and performance problems. Repair: Comprehensive step-by-step instructions for all major component repairs. Rebuild: Detailed procedures for engine and component rebuilds. Tuning: Carburetor tuning, ignition timing adjustments (where applicable). Technical Depth Depth: Factory-level detail covering routine maintenance to complete engine and component overhauls. Diagnostic Techniques: Includes 'secret techniques' used by top mechanics for part testing and diagnosis. Wiring Diagrams: Detailed and traceable wiring diagrams for the entire electrical system. Engine Management Systems: Understanding and analysis of engine management systems (if applicable to these models). Illustrations Diagrams: Includes hundreds of illustrations, drawings, and photos to guide procedures. Formatting Features: Detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers, enlarged insets. 📊 Manual Specifications File Format Format: PDF Accessibility: Viewable and printable on PC (Windows) and Mac. Searchability: Searchable functionality for quick information retrieval. Print Quality Printability: Printable without restriction (entire manual or specific pages). Resolution: High resolution Binding Type Delivery Method: Digital Download Physical Format: Not applicable (digital delivery) Paper Type Storage Options: Save to hard-drive, burn to CD-ROM. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke (typical for EXC/SX models of this era; specific details would be in the manual). Engine Variants: 400cc, 450cc, 520cc (specific cubic capacities would be detailed within the manual). Performance Horsepower: Specifications for each engine variant available in the manual. Torque: Specifications for each engine variant available in the manual. Fuel System Carburetion: Details on the specific carburetor used (e.g., Keihin FCR, Mikuni) and its tuning. 🔧 Transmission Standard Transmission Type: Manual, multi-gear (typical for these models, specific number of gears to be found in manual). Optional Optional Gearbox Ratios: If different gearbox options or ratios were available, they would be detailed in the manual. Features Clutch Type: Wet multi-plate clutch (standard for KTM off-road bikes of this period). 📐 Dimensions Exterior Body Style: Dual-sport/Enduro/Motocross motorcycle. Weights Dry Weight: Specifications for each model variant (e.g., 450 EXC, 520 SX) would be detailed in the manual. Wet Weight: Specifications for each model variant (e.g., 450 EXC, 520 SX) would be detailed in the manual. 🛡️ Safety Features Ratings Safety Features: Focus on mechanical safety features such as reliable braking systems, robust frame construction. Active Features Braking System Type: Hydraulic disc brakes front and rear (typical). Passive Features Frame Material: Chromoly steel frame (typical for KTM off-road bikes). 💡 Technology Features Infotainment Features: Primarily mechanical and electrical systems; no advanced infotainment features expected on these off-road models. Driver Assistance Features: No electronic driver assistance systems typically found on these off-road oriented machines. Connectivity Features: No wireless or...