This Workshop Service Manual (WSM) provides comprehensive service, repair, and maintenance information for SX, MXC, and EXC models produced between 2000 and 2003. These high-performance off-road motorcycles, available with engine displacements ranging from 250cc to 525cc, are known for their Austrian engineering, racing heritage, and robust construction. The SX series is tailored for motocross, while the EXC models are designed for enduro riding, both benefiting from deep roots in motorsports. This manual covers a wide array of specific variants within these series, ensuring detailed guidance for each. This manual serves as an indispensable resource for owners, technicians, and mechanics, offering in-depth, professional-grade coverage of all major vehicle systems. It includes detailed step-by-step procedures for engine mechanical and electrical systems, fuel and transmission operations, suspension and brake servicing, as well as frame and bodywork maintenance. Crucial information on routine maintenance, troubleshooting common issues, specialized tool usage, and technical specifications is also provided. By following the comprehensive instructions and diagrams within this manual, users can effectively maintain, diagnose, and repair their off-road motorcycles, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Covered Years: 2000, 2001, 2002, 2003 Engine Displacements Covered: 250cc, 400cc, 450cc, 520cc, 525cc Codes Manual Type: Workshop Service Manual (WSM) 👋 Introduction Market Position Target Audience: Owners and technicians working on KTM SX, MXC, and EXC off-road motorcycles from the 2000-2003 model years. Competitive Analysis Value Proposition: Provides essential, in-depth technical data for maintaining and repairing these high-performance off-road machines, crucial for optimizing performance and longevity. Key Features Manual Advantage: Offers detailed OEM-level repair procedures, vital for accurate and efficient servicing of KTM's specialized off-road platforms. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance for KTM SX, MXC, and EXC models. Specific Models: 250 SX, 250 MXC, 250 EXC, 400 SX, 400 MXC, 400 EXC, 450 SX, 450 MXC, 450 EXC, 520 SX, 520 MXC, 520 EXC, 525 SX, 525 MXC, 525 EXC Page Count Estimated Page Count: High, likely 500+ pages (typical for comprehensive WSMs of this era). Manual Type Manual Type: Service and Repair Manual Language Language: English (presumed, standard for professional manuals) Format Format: Digital (PDF) or Printed 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair for all specified displacements. Engine Electrical: Ignition system, starting system, charging system, wiring diagrams, component testing. Fuel System: Carburetor tuning and overhaul (likely Mikuni or Keihin variants), fuel pump, fuel lines, tank. Transmission: Clutch operation, gearbox disassembly, assembly, inspection, lubrication. Suspension: Front fork (WP USD) service, seal replacement, oil levels, damping adjustments. Rear shock absorber service, spring preload, damping. Brakes: Hydraulic brake system (front and rear), caliper service, master cylinder overhaul, pad replacement, fluid bleeding, rotor inspection. Electrical System: Lighting, battery, CDI unit, wiring diagrams, troubleshooting electrical faults. Cooling System: Radiator, hoses, thermostat (if applicable), coolant type and capacity. Frame And Bodywork: Chassis inspection, swingarm, linkages, seat, fenders, fuel tank, handlebars. Wheels And Tires: Wheel bearing service, spoke tensioning, tire replacement, recommended tire pressures. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, spark plug checks, air filter cleaning. Troubleshooting: Diagnostic procedures for common performance issues, electrical faults, and mechanical problems. Rebuilds: Complete engine and transmission rebuild procedures with torque specifications. Adjustments: Valve clearance adjustment, carburetor synchronization, suspension damping adjustments. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Depth Level: Professional-grade, in-depth coverage suitable for experienced mechanics and advanced DIY enthusiasts. Detail Level: Detailed step-by-step instructions, exploded views, diagrams, and specifications. 📊 Manual Specifications File Format Digital Format: PDF (searchable text and high-resolution images expected) Print Quality Print Quality: Professional quality with clear diagrams and sharp text. Binding Type Binding Type: Comb binding, wire-o binding, or perfect binding (for printed versions). Paper Type Paper Type: Durable, gloss-coated paper stock suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke (OHC, 4-valve typically for these models). Cooling System: Liquid-cooled (radiators). Performance 250Cc Power Estimate: ~30-35 HP (estimated, varies by model variant) 525Cc Power Estimate: ~45-50 HP (estimated, varies by model variant) Fuel System Carburetor Type: Mikuni TM40/TM42 or Keihin FCR (common for this era). Fuel Type: Unleaded gasoline (RON 95/98 recommended). 🔧 Transmission Standard Transmission Type: 5-speed or 6-speed constant mesh gearbox (depending on specific model variant). Clutch Type: Wet multi-plate clutch. Features Transmission Fluid: KTM recommends specific mineral-based gear oil or high-quality motorcycle transmission oil (refer to manual for exact specs). 📐 Dimensions Exterior Frame Type: Chromium-molybdenum steel trellis frame. Weights Dry Weight Estimate: ~100-115 kg (220-250 lbs) depending on model and displacement. 🛡️ Safety Features Ratings Safety Features Focus: Focus on rider control and chassis stability rather than passive safety features found in street vehicles. Active Features Braking System: Hydraulic disc brakes front and rear (Brembo components common). 💡 Technology...