This workshop service and repair manual covers the 450 EXC, 400 EXC, and 520 SX models manufactured between 2000 and 2003. These high-performance off-road motorcycles are renowned for their powerful four-stroke engines, advanced suspension systems, and robust construction, making them popular choices for enduro and motocross enthusiasts. Engineered for demanding terrain, these models have a strong heritage in off-road racing, consistently competing against major manufacturers with their focus on performance, reliability, and rider control. This comprehensive manual provides detailed guidance for the maintenance, repair, and troubleshooting of your motorcycle. It includes step-by-step procedures for engine disassembly and assembly, transmission servicing, fuel and ignition system maintenance, suspension and brake system overhauls, and electrical system diagnostics. Essential technical specifications, including torque values, fluid capacities, and component clearances, are also provided. This manual is an indispensable resource for owners and technicians seeking to ensure their 400 EXC, 450 EXC, or 520 SX operates at peak performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC, 400 EXC, 520 SX Model Years: 2000, 2001, 2002, 2003 Codes Manual Identifier: Workshop Service Repair Manual 👋 Introduction Market Position Category: High-performance off-road motorcycles (Enduro/Motocross). Target Audience: Owners, mechanics, and enthusiasts of KTM 400 EXC, 450 EXC, and 520 SX models from the specified years. Competitive Analysis Competitors: During the 2000-2003 period, key competitors included Yamaha WR series, Honda CRF/XR series, Suzuki DR-Z series, and Kawasaki KX/KDX series motorcycles. Key Features Manual Value Proposition: Provides comprehensive, authoritative guidance for maintaining and repairing these specialized off-road KTM models, empowering owners to perform tasks themselves or understand complex repairs. Vehicle Attributes: Known for their powerful engines, advanced suspension, and robust off-road capability, making them popular for competition and serious trail riding. 📋 Manual Details Coverage Areas Covered Models: KTM 450 EXC, KTM 400 EXC, KTM 520 SX Covered Years: 2000-2003 Page Count Estimated Page Count: High (typically 300-500+ pages for this level of detail) Manual Type Type: Complete Workshop Service and Repair Manual Language Language: English Format Format: Downloadable (likely PDF) 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, troubleshooting, and overhaul for all engine variants (400cc, 450cc, 520cc) including valve clearance, piston, cylinder, crankshaft, and lubrication system. Transmission: Complete coverage of gearbox disassembly, assembly, inspection, and repair, including clutch operation and adjustment. Fuel System: Carburetor (likely Keihin or Mikuni) tuning, cleaning, rebuilding, and troubleshooting; fuel tank and petcock maintenance. Ignition System: CDI ignition system diagnostics, troubleshooting, and component testing (stator, coil, spark plug). Cooling System: Radiator, coolant hoses, water pump, and thermostat maintenance and inspection. Suspension: Front fork (e.g., WP USD) and rear shock absorber service, including oil changes, seal replacement, and adjustments. Brakes: Front and rear hydraulic brake system service, including caliper overhaul, pad replacement, fluid bleeding, and master cylinder inspection. Electrical System: Wiring diagrams, battery maintenance, lighting system, and troubleshooting of electrical faults. Chassis And Frame: Frame inspection, steering head bearing service, and general chassis component maintenance. Wheels And Tires: Wheel bearing inspection and replacement, spoke tensioning, and tire pressure recommendations. Exhaust System: Exhaust pipe and muffler inspection and maintenance. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, chain adjustment and lubrication, air filter cleaning/replacement, spark plug inspection, valve clearance checks. Disassembly And Assembly: Complete step-by-step instructions for engine, transmission, suspension, and braking system components. Troubleshooting: Diagnostic procedures for common problems related to starting, running, electrical systems, and performance. Repair And Overhaul: Detailed instructions for rebuilding carburetors, engines, transmissions, and suspension components. Wiring Diagrams: Comprehensive electrical schematics for all systems. Specifications And Torques: Essential torque values, clearances, fluid types, and capacities for all components. Technical Depth Depth: Comprehensive. Covers everything from basic maintenance to full engine and component rebuilds, including advanced diagnostics and troubleshooting. 📊 Manual Specifications File Format Format: PDF (Portable Document Format), allowing for easy viewing, searching, and printing. Print Quality Quality: High-resolution scans ensuring clarity of text, diagrams, and illustrations. Binding Type Binding: N/A (Downloadable format) Paper Type Type: N/A (Downloadable format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled. Bore X Stroke: Varies by model (e.g., 400 EXC: ~86 x 70 mm, 450 EXC: ~95 x 63.4 mm, 520 SX: ~95 x 72 mm - specific values available in manual). Displacement: 400cc, 450cc, 520cc. Performance Horsepower: Varies by model and tuning, typically in the range of 40-55 HP (exact figures available in manual). Torque: Significant torque delivery optimized for off-road conditions (specific figures available in manual). Fuel System Carburetor Type: Keihin FCR (Flat CR) or Mikuni VM series (specific model dependent, manual will confirm). Fuel Type: Unleaded gasoline, 91-98 RON (Octane Rating) recommended. Lubrication Oil Type: High-quality synthetic 4-stroke motorcycle oil (e.g., Motorex, Castrol) with JASO MA rating. Specific viscosity (e.g., 10W-40, 15W-50) and capacity detailed in manual. Engine Codes Engine Identification: Engine serial numbers are typically located on the crankcase (specific location detailed in manual). 🔧...