This manual covers a range of off-road motorcycles from the 2000 to 2003 model years, specifically the SX, MXC, EXC, EGS, and EXC Racing series, equipped with LC4 4-stroke engines in displacements of 250, 400, 450, 520, and 525cc. These models represent a strong heritage in off-road competition, designed for demanding use in motocross, cross-country, and enduro disciplines. Known for their robust chromium-molybdenum steel trellis frames and powerful, torque-rich LC4 engines, these motorcycles are built with a 'Ready to Race' philosophy, emphasizing performance and durability in challenging environments. This comprehensive workshop service repair manual provides detailed instructions for maintenance, troubleshooting, and repair. It covers essential areas including engine disassembly and reassembly, servicing of internal engine components, carburetor maintenance, electrical system diagnostics with wiring diagrams, chassis system servicing, and suspension adjustments. The manual is designed to assist DIY enthusiasts, home mechanics, and professional technicians in performing routine maintenance, such as oil changes and air filter cleaning, as well as more complex repairs and full engine rebuilds, ensuring the optimal performance and longevity of these high-performance motorcycles. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC, EGS, EXC Racing Model Variants: 250, 400, 450, 520, 525 Years Covered: 2000, 2001, 2002, 2003 Generation Generation Identifier: LC4 4-Stroke Era (Early) 👋 Introduction Market Position Target Audience: DIY enthusiasts, home mechanics, and professional technicians working on KTM off-road motorcycles. Competitive Analysis Value Proposition: Provides essential technical information and repair procedures for a range of popular KTM models, enabling cost-effective maintenance and repair. Key Features Manual Benefits: High-quality diagrams, comprehensive coverage, instant download for immediate access, cost savings on postage and packaging. Diagram Quality: Contains high-quality diagrams essential for understanding complex assemblies and procedures. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for 2000-2003 KTM 4-stroke off-road models. Page Count Estimated Page Count: Varies by specific model and engine size, but generally extensive for a workshop manual. Manual Type Manual Classification: Workshop Service Repair Manual Language Primary Language: English Text Searchability: PDF format typically allows for text searching of keywords. Format Digital Format: PDF File Format Compatibility: Compatible with all versions of Windows & Mac. 📖 Manual Coverage Systems Covered Engine Systems: Engine removal and refitting, disassembly, component servicing, assembly, troubleshooting. Electrical Systems: Wiring diagrams, troubleshooting electrical issues. Chassis Systems: Frame inspection, suspension (front forks, rear shock absorber) service and adjustment, wheel bearing maintenance. Fuel System Components: Carburetor removal, cleaning, adjustment, and troubleshooting. Cooling System: Radiator and hose inspection, coolant replacement, troubleshooting overheating. Procedures Included Maintenance Procedures: Periodic maintenance schedule, fluid changes, filter replacements, general servicing. Repair Procedures: Detailed step-by-step instructions for engine and component repair. Torque Specifications: Crucial torque values for critical fasteners throughout the engine and chassis are provided. Troubleshooting Flowcharts: Likely includes structured troubleshooting guides for common starting, running, and performance issues. Technical Depth Diagnostic Capabilities: Troubleshooting guides for common issues, technical specifications for accurate diagnosis. Rebuild Depth: Complete engine disassembly and reassembly procedures suitable for full rebuilds. 📊 Manual Specifications File Format File Type: PDF Software Requirement: Adobe PDF Reader. Print Quality Printability: All pages are printable. Binding Type Binding Method: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled Single Cylinder (LC4 engine family) Performance Displacement Range: 250cc, 400cc, 450cc, 520cc, 525cc Bore Stroke Variations: Specific bore and stroke dimensions vary significantly across the 250, 400, 450, 520, and 525cc displacements. Fuel System Fuel Delivery System: Primarily Carbureted (Mikuni or Keihin, specific model dependent), potential for early fuel injection on some late models/variants, though unlikely for this specific year range in this context. Engine Design Valve Train: SOHC or DOHC (depending on specific engine variant within the LC4 family, though SOHC is more prevalent for earlier models in this range). Cooling System: Liquid-cooled via radiator and fan (electric fan on some models/years). 🔧 Transmission Standard Transmission Type: 5-speed or 6-speed manual gearbox (specific to model and year). Optional Clutch Type: Wet, multi-plate clutch (hydraulic actuation common). Features Drive System: Chain drive (rear wheel). Gear Ratios: Gear ratios are specific to each model and engine size and would be detailed within the manual. 📐 Dimensions Exterior Chassis Type: Chromium-molybdenum steel trellis frame. Suspension Type Front: Upside-down (USD) telescopic forks (e.g., WP). Suspension Type Rear: Monoshock with linkage (e.g., WP). Weights Dry Weight Range: Approximately 105-120 kg (231-265 lbs), varies significantly by model and engine size. 🛡️ Safety Features Ratings Safety Standards: N/A (Off-road competition motorcycles, typically not subjected to DOT/NHTSA safety ratings). Active Features Braking System: Hydraulic disc brakes front and rear (Brembo calipers common). Passive Features Frame Integrity: Robust steel trellis frame designed for off-road stress. 💡 Technology Features Infotainment Display System: Basic LCD display showing trip meter, odometer, clock, and neutral indicator. No advanced infotainment. Driver Assistance ABS Availability: ABS was not a standard or...