🏷️ Basic Information Identification Make: KTM Model: 450 EXC, 400 EXC, 520 SX Model Variant Identifier: Dual-sport and Motocross variants Codes Production Years Covered: 2000, 2001, 2002, 2003 👋 Introduction Market Position Category: High-performance off-road motorcycles Target Audience: Enduro and motocross riders, mechanics, technical enthusiasts Competitive Analysis Competitors: Honda CRF series, Yamaha YZ/WR series, Suzuki RM/RMX series, Kawasaki KX/KLX series Key Features Manual Value Proposition: Provides essential technical knowledge for maintaining and repairing sought-after KTM models Vehicle Appeal: Renowned for power, agility, and off-road capability 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, maintenance, and repair Secondary Coverage: Troubleshooting, diagnostics, technical specifications Page Count Estimated Page Count: Varies by specific model and year; typically 300-500 pages for full workshop manuals Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, inspection, repair (cylinder head, piston, crankshaft, connecting rod, valve train), lubrication system, cooling system, starting system Fuel System: Carburetor overhaul and adjustment, fuel tank, fuel lines, fuel pump (if applicable) Transmission: Clutch operation, gearbox disassembly and reassembly, gear shift mechanism Electrical System: Ignition system, lighting system, charging system, wiring diagrams, fault finding Chassis: Frame, suspension (forks, rear shock absorber), steering system, wheels and tires Brakes: Front and rear brake systems (hydraulic, caliper, master cylinder, brake lines, brake pads, brake discs) Exhaust System: Exhaust pipe, muffler, mounting Bodywork: Plastic body panels, seat, fuel tank cover, fenders Procedures Included Maintenance: Routine service, oil changes, filter replacement, chain adjustment, lubrication points, valve clearance checks Repair: Engine rebuilds, transmission repairs, suspension overhauls, brake system servicing, electrical component replacement Troubleshooting: Diagnostic flowcharts, common problems and solutions, electrical fault tracing Technical Specifications: Torque values, clearances, fluid capacities, part numbers, engine specifications Technical Depth Depth: In-depth, suitable for professional mechanics and experienced DIY enthusiasts 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Likely text-searchable (depending on original scan quality) Print Quality Printability: Designed for digital viewing and printing of individual pages or sections Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder (liquid-cooled, SOHC) Displacement 400Exc: Approx. 398cc Displacement 450Exc: Approx. 450cc Displacement 520Sx: Approx. 510-520cc Performance Horsepower Estimate: Varies by model and tuning, generally 45-60+ HP Torque Estimate: Strong mid-range and top-end torque characteristic of KTM off-road engines Fuel System Fuel Delivery: Carburetor (e.g., Keihin PWK series) Fuel Type: Unleaded gasoline (premium recommended) Ignition Ignition System: Digital CDI with variable ignition timing 🔧 Transmission Standard Type: 5-speed or 6-speed manual gearbox (depending on specific model variant) Features Clutch: Hydraulic, multi-plate wet clutch Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase Estimate: Approx. 1470-1485 mm (57.9-58.5 in) Weights Dry Weight Estimate: Approx. 110-125 kg (242-275 lbs) 🛡️ Safety Features Ratings Safety Certification: Off-road vehicles typically not subject to DOT safety ratings in the same way as street vehicles. Active Features Braking System: Powerful hydraulic disc brakes front and rear Passive Features Frame Construction: Chromium-molybdenum steel trellis frame for strength and rigidity 💡 Technology Features Infotainment Features: N/A (basic off-road focused electronics) Driver Assistance Features: N/A Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 15-30 hours of riding or annually, depending on usage severity. Specifics in manual. Air Filter Cleaning: Frequent cleaning recommended, especially in dusty conditions; interval varies with environment. Valve Clearance Check: Typically every 30-50 hours of riding. Crucial for engine health. Fluid Specifications Engine Oil Type: High-quality synthetic 4-stroke motorcycle oil, SAE 10W-40 or 15W-50 (refer to manual for exact viscosity based on temperature range). Engine Oil Capacity: Approx. 1.0-1.3 liters (refer to manual for exact capacity with or without filter change). Coolant Type: Ethylene glycol-based antifreeze/coolant mixture (50/50 with distilled water). Brake Fluid Type: DOT 4 hydraulic brake fluid. Known Issues Common Wear Items: Clutch plates, piston rings, valve guides, wheel bearings, chain and sprockets. Potential Failures: Carburetor jetting issues, stator failures, starter motor problems (less common on early models if maintained), shock absorber seal leaks. Maintenance Tips Pre Ride Checks: Tire pressure, chain tension, fluid levels, brake function, fastener security. 📚 Vehicle History Brand Heritage Manufacturer Origin: Austria Brand Focus: Specializes in high-performance off-road motorcycles, racing heritage Model Evolution Development Context: These models represent a period of significant development for KTM's 4-stroke off-road platform, building on earlier designs and racing success. Production Production Era: Early 2000s 🏆 Awards & Recognition Recognitions Market Reputation: KTM models from this era are highly regarded for their performance and durability in off-road competition and trail riding. Ratings Editorial Reviews: Frequently praised for powerful engines and capable chassis. Specific awards would require searching contemporary motorcycle publications.