This manual covers SX, MXC, and EXC models from the 2000, 2001, 2002, and 2003 model years, featuring single-cylinder, four-stroke engines with displacements ranging from 250cc to 525cc. The brand is renowned for its high-performance off-road motorcycles, and these models represent a significant period of development in their four-stroke technology, offering competitive chassis and potent engine performance. These versatile machines are engineered for motocross, cross-country, and enduro riding, built with the quality and durability expected from the brand's racing heritage. This comprehensive Service Repair Workshop Manual provides factory-level information in English for owners and mechanics. It details routine maintenance, periodic checks, lubrication, and step-by-step repair instructions for all major systems, including the engine, fuel, cooling, transmission, electrical, suspension, and bodywork. With detailed specifications, troubleshooting guidance, and clear illustrations and wiring schematics, this manual is an essential resource for maintaining and repairing your motorcycle, enabling efficient servicing and informed decision-making. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Applicable Model Years: 2000, 2001, 2002, 2003 Engine Variants Covered: 250cc, 400cc, 450cc, 520cc, 525cc Codes Manual Code: Not specified (vehicle specific) 👋 Introduction Market Position Target Audience: KTM owners, independent mechanics, service professionals Value Proposition: Enables cost savings on maintenance and repairs, empowers informed decision-making. Competitive Analysis Uniqueness: Vehicle-specific, factory-level information, not generic. Key Features Content Features: Step-by-step instructions, diagrams, illustrations, wiring schematics, specifications, troubleshooting. Benefit 1: Facilitates easy and safe servicing and repair for users with basic mechanical knowledge. Benefit 2: Reduces reliance on expensive dealership service. Accessibility: Viewable on PC, Mac, phones, and e-readers; printable pages. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Scope: Comprehensive for mechanics and owners Page Count Estimated Page Count: Large (exact number not provided, but described as 'full' and 'complete') Manual Type Type: Service Repair Workshop Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine Specifications, Engine Removal and Installation, Intake & Exhaust Fuel System: Fuel System Cooling System: Cooling System Transmission Drivetrain: Transmission, Drive Chain, Sprockets Electrical System: Electrical System, Wiring Diagram Suspension Steering: Steering System, Shocks Bodywork: Body Work Procedures Included Maintenance: Routine Maintenance, Periodic Checks and Adjustments, Lubrication Repair: Step-by-step repair instructions for all covered systems Diagnostics: Advanced Troubleshooting Troubleshooting: Integrated troubleshooting guidance Technical Depth Depth: Comprehensive, detailed, factory-level information Diagrams: Diagrams, Illustrations Wiring Schematics: Detailed Wiring Schematics 📊 Manual Specifications File Format Format: PDF Compatibility: All Versions of Windows and Mac Requirements: Adobe PDF Reader Print Quality Printability: Yes, all pages printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Types: Single-cylinder, four-stroke engines Displacements Covered: 250cc, 400cc, 450cc, 520cc, 525cc Performance Horsepower Range: Varies by model and displacement (specific figures not in description, but covered in manual) Torque Range: Varies by model and displacement (specific figures not in description, but covered in manual) Fuel System Fuel Delivery: Carburetor (typical for this era, specific details in manual) Engine Specifications Coverage Coverage: Detailed engine specifications provided in the manual. 🔧 Transmission Standard Transmission Type: Likely 6-speed manual (typical for SX/MXC/EXC models of this era) Optional Optional Transmissions: Not applicable for these off-road models Features Gear Ratios: Specific gear ratios for each model and variant are detailed in the manual. Clutch Type: Hydraulic wet multi-plate clutch (typical for KTM off-road) 📐 Dimensions Exterior Body Style: Dirt Bike / Motocross / Enduro Weights Dry Weight: Varies by model and displacement (specific figures covered in manual) 🛡️ Safety Features Ratings Safety Ratings: Not applicable for off-road motorcycles in the same way as cars. Active Features Active Safety: Focus on rider skill and vehicle control; manual covers braking system maintenance. Passive Features Passive Safety: Frame integrity, suspension damping, rider protection equipment (not covered in manual itself). 💡 Technology Features Infotainment Infotainment Systems: Not applicable to these models, which are focused on performance and off-road capability. Driver Assistance Driver Assistance Features: Not applicable. Connectivity Connectivity Features: Not applicable. Electrical System Lighting: Basic lighting systems (headlight, taillight) for trail riding, detailed in electrical section. 🔧 Maintenance Service Intervals Routine Maintenance: Covered extensively, including oil changes, filter cleaning/replacement, chain adjustment, spark plug checks. Periodic Checks: Detailed schedules for checks and adjustments are provided. Fluid Specifications Engine Oil: Specific oil viscosity grades and API specifications (e.g., SAE 10W-50, JASO MA) are detailed in the manual. Coolant: Recommended coolant type and mixture ratio (e.g., ethylene glycol-based) are specified. Brake Fluid: DOT 4 or DOT 5.1 brake fluid typically recommended (specifics in manual). Gear Oil: Specific gear oil specifications and capacities are provided. Known Issues Common Wear Items: Piston rings, valve guides, clutch plates, chain and sprockets are typical wear items for high-performance off-road motorcycles of this era. Manual provides inspection and replacement procedures. Carburetor Tuning: Carburetor jetting and adjustment are critical for optimal performance at different altitudes...