🏷️ Basic Information Identification Make: KTM Model: 520 SX / 525 SX Year Range: 2000-2006 Codes Chassis Codes: Pre-2007 models, generally identified by engine displacement and the SX designation for motocross. Specific chassis codes may vary by year and sub-model within the SX range. 👋 Introduction Market Position Market Segment: Performance Motocross / Off-Road Motorcycles Competitive Analysis Competitors: Competed against models from Yamaha (YZ series), Honda (CRF series), Suzuki (RM series), Kawasaki (KX series) during its production run. Known for potent engines and capable chassis. Key Features Features: Powerful four-stroke engines (520cc and 525cc variants), competitive suspension, lightweight chassis, focus on performance for motocross racing and aggressive off-road riding. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for KTM 520 SX and 525 SX models from 2000 to 2006. Page Count Estimated Page Count: 300-400 pages (typical for a complete service manual of this era for a performance motorcycle). Manual Type Type: Service Manual / Repair Manual Supplemental Manuals Indicated: May refer to or complement owner's manuals or parts catalogs, but this is the core service document. Language Language: English Format Format: Likely a printed manual or a high-quality PDF reproduction. 📖 Manual Coverage Systems Covered Engine: Top end (cylinder, piston, valves, camshaft), bottom end (crankshaft, connecting rod, bearings), lubrication, cooling system, ignition system, fuel system (carburetor tuning and components), exhaust system. Transmission: Clutch operation and service, gearbox components, shifting mechanisms, lubrication. Electrical: Wiring diagrams, lighting system, ignition coil, CDI unit, stator, rectifier/regulator, battery maintenance, starter system (if applicable to specific variants), troubleshooting electrical faults. Chassis: Frame inspection, suspension (forks and rear shock absorber maintenance and adjustments), wheel bearing service, steering head bearing service, brake system (front and rear caliper, master cylinder, brake lines, pad replacement), control cables (throttle, clutch). Frame And Swingarm: Frame inspection, alignment checks, swingarm bearing service, linkage maintenance (if applicable to rear suspension design). Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment, air filter cleaning/replacement. Repair: Engine disassembly and reassembly (full rebuild capabilities), transmission overhaul, suspension fork seal replacement, brake system bleeding and component replacement, carburetor overhaul, electrical component testing and replacement. Troubleshooting: Diagnostic procedures for common running issues, starting problems, electrical faults, and mechanical noises. Special Tools: Includes lists and usage instructions for specialized tools required for certain procedures (e.g., flywheel puller, valve spring compressor, torque wrenches). Technical Depth Depth: Detailed specifications, service limits, torque values, special tool requirements, and step-by-step repair instructions for professional-level maintenance and repair. 📊 Manual Specifications File Format Digital Format Quality: High-resolution, searchable PDF with clear diagrams and text if digital. Print Quality Print Quality: Clear, legible print with high-contrast diagrams and photographs if printed. Binding Type Binding: Spiral-bound or lay-flat binding for workshop convenience if printed. Paper Type Paper Type: Durable, matte paper stock suitable for workshop environments if printed. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Bore X Stroke 520: Approx. 95 mm x 72 mm (specifics vary by exact sub-model, consult manual for definitive figures) Bore X Stroke 525: Approx. 97 mm x 73.2 mm (specifics vary by exact sub-model, consult manual for definitive figures) Displacement 520: 520cc (approximate) Displacement 525: 525cc (approximate) Valve Train: SOHC (Single Overhead Camshaft), 4 valves per cylinder. Ignition System: Digital CDI with variable ignition timing (typically Kokusan or similar). Performance Horsepower Estimate: 50-55 HP range (typical for this displacement and era performance dirt bikes, peak figures vary) Torque Estimate: 45-50 lb-ft range (estimated peak torque, varies) Compression Ratio: Varies by year and specific engine tune, typically in the range of 11.5:1 to 13:1. Consult manual for exact specification. Fuel System Carburetor Type: Keihin FCR flat-slide carburetor (e.g., FCR 39, FCR 41 - specific size depends on year/model) Fuel Type: Unleaded gasoline, 91 octane or higher recommended. 🔧 Transmission Standard Transmission Type: 5-speed manual transmission Optional Transmission Options: None (standard 5-speed manual) Features Clutch Type: Hydraulically operated multi-plate wet clutch. Gear Ratios: Specific gear ratios are detailed within the manual and crucial for performance tuning. Clutch Actuation: Hydraulic clutch actuation for smoother engagement and reduced lever effort. 📐 Dimensions Exterior Wheelbase: Variable by year, typically around 58-59 inches (consult manual for exact specification). Seat Height: Variable by year, typically around 37-38 inches (consult manual for exact specification). Front Tire Size: Typically 80/100-21 (consult manual for precise size and recommended pressures). Rear Tire Size: Typically 110/90-19 or 100/90-19 (consult manual for precise size and recommended pressures). Weights Dry Weight: Approx. 235-245 lbs (107-111 kg) - varies by year and specific components. Consult manual for accurate figure. 🛡️ Safety Features Ratings Safety Ratings: Not applicable to off-road motorcycles in the same way as street vehicles. Focus is on rider control and machine reliability. Active Features Active Safety: Effective braking system (hydraulic disc brakes front and rear), responsive suspension, ergonomic...