This manual covers the 2000 model year motorcycles, available with engine displacements of 250cc, 400cc, 450cc, 520cc, and 525cc. These Austrian-manufactured machines are renowned for their off-road performance, building on a strong heritage in motorsports. The SX models are designed for motocross, the MXC for cross-country racing, and the EXC for enduro riding, each offering a robust Chromium-molybdenum steel perimeter frame and liquid-cooled, single-cylinder, 4-stroke engines. These motorcycles are engineered for demanding off-road conditions, emphasizing power, agility, and rider control. This comprehensive service repair manual provides detailed instructions for the maintenance, repair, and troubleshooting of all 2000 models. It covers essential systems including the engine, drivetrain, chassis, braking, and electrical components, with specific procedures for assembly, disassembly, tuning, and rebuilding. The manual includes routine maintenance schedules, fluid specifications, troubleshooting guides, and detailed wiring diagrams. Its purpose is to assist professional technicians, experienced DIY mechanics, and owners in effectively maintaining and repairing their motorcycles, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Year: 2000 Engine Variants: 250cc, 400cc, 450cc, 520cc, 525cc Codes Model Code Indication: SX (Motocross), MXC (Cross-Country), EXC (Enduro) 👋 Introduction Market Position Target Audience: Professional technicians, experienced DIY mechanics, and owners seeking in-depth knowledge for maintenance and repair Competitive Analysis Manual Advantage: Provides the same level of detail as professional workshop manuals, accessible digitally for immediate use Key Features Instructional Clarity: Numbered instructions, sub-steps, notes, cautions, and warnings for clarity and safety Visual Guidance: Detailed illustrations, drawings, photos, and enlarged insets for precise part identification and procedural understanding Navigation: Numbered table of contents for quick information retrieval 📋 Manual Details Coverage Areas Primary Coverage: All KTM 250, 400, 450, 520, 525 SX, MXC, EXC models for the 2000 model year Page Count Estimated Page Count: Likely extensive, often exceeding 500 pages for full service manuals covering multiple variants Manual Type Manual Classification: Full Service Repair Manual Language Language Of Publication: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly, disassembly, tuning, cooling system, lubrication system, fuel system (carburetion), exhaust system Drivetrain Systems: Transmission, clutch, final drive (chain and sprockets), gearbox disassembly and assembly Chassis Systems: Frame, suspension (forks, rear shock absorber), steering, wheels, hubs, spokes Braking Systems: Front and rear brake systems (hydraulic disc brakes), caliper overhaul, master cylinder service, bleeding procedures Electrical Systems: Ignition system, lighting system, charging system (stator, regulator/rectifier), wiring diagrams, troubleshooting electrical faults Bodywork And Controls: Handlebars, levers, footpegs, seat, plastic body panels, decals Procedures Included Maintenance Procedures: Routine maintenance checks, oil changes, filter replacements, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement Repair Procedures: Detailed step-by-step instructions for engine rebuilds, transmission repairs, suspension servicing, brake component replacement, electrical diagnostics and repair Troubleshooting: Diagnostic guides for common problems, symptom-based troubleshooting, electrical system troubleshooting with wiring diagrams Rebuilding Procedures: Comprehensive instructions for rebuilding engine components (pistons, rings, valves, crankshaft), carburetor overhaul, shock absorber servicing Technical Depth Diagnostic Capabilities: Advanced diagnostics for engine performance issues, ignition timing, electrical system faults Rebuild Scope: Full engine, transmission, and suspension component rebuilds are covered in detail Electrical Diagrams: Detailed and integrated wiring diagrams for all electrical systems 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Full Printable, allowing users to print specific pages or the entire manual Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) Delivery Download Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke (typical for these models, although some early variations might exist) Performance Power Output: Varies by displacement: 250cc (approx. 30-35 hp), 400cc (approx. 40-45 hp), 450cc (approx. 45-50 hp), 520cc/525cc (approx. 50-55+ hp). Specific figures require model-year confirmation. Torque Output: Varies by displacement and tune. Generally higher torque figures for larger displacements. Fuel System Fuel Delivery: Carburetor (e.g., Keihin PJ/PWK series or similar for the era) Carburetor Details: Specific jetting, needle positions, and adjustments for different engine sizes and models will be detailed in the manual. Ignition System Ignition Type: Digital CDI ignition system Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: Constant-mesh, 5 or 6-speed sequential gearbox Optional Clutch Type: Hydraulically actuated, multi-plate wet clutch Features Gear Ratios: Specific gear ratios for each model variant and transmission type will be provided in the manual. 📐 Dimensions Exterior Frame Type: Chromium-molybdenum steel perimeter frame (typical KTM construction) Weights Dry Weight: Typically in the range of 100-115 kg (220-250 lbs) depending on the specific model and displacement. Actual figures will be in the manual. 🛡️ Safety Features Ratings Safety Features: Primarily focused on rider safety through proper maintenance and functional components. No formal crash ratings for off-road motorcycles. Active Features Braking Performance: Hydraulic disc brakes front and rear, ensuring effective stopping power....