This service and repair manual covers SX, MXC, and EXC models from the 2000 to 2003 model years, featuring engine variants of 250cc, 400cc, 450cc, 520cc, and 525cc. Built upon a strong racing heritage, these off-road motorcycles are designed for high performance in motocross, cross-country, and enduro disciplines. Known for their robust engineering and competitive edge, these models represent a significant era in the development of powerful and agile off-road machines, consistently proving their mettle in demanding racing environments. This comprehensive manual provides detailed, step-by-step instructions for all aspects of maintenance, repair, and refurbishment. It covers essential systems including the engine, fuel system, cooling system, electrical system, chassis, and emission control information. Whether you are a dedicated enthusiast performing routine upkeep or a professional technician undertaking complex rebuilds, this manual offers the in-depth knowledge, diagnostic procedures, and troubleshooting guidance necessary to keep your motorcycle in peak condition. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Engine Variants: 250cc, 400cc, 450cc, 520cc, 525cc Model Years Covered: 2000, 2001, 2002, 2003 Codes Manual Type: Service and Repair Manual 👋 Introduction Market Position Market Position: Targeted at owners of KTM's high-performance off-road motorcycles (SX for Motocross, MXC for Cross-Country, EXC for Enduro) from the early 2000s, who need comprehensive resources for maintenance and repair. Competitive Analysis Competitive Analysis: This manual positions itself as a cost-effective solution for KTM owners, offering professional-grade repair and maintenance information that rivals factory service manuals in scope, enabling users to perform tasks typically handled by dealerships. Key Features Key Features: Offers comprehensive coverage for multiple engine sizes and model designations within a specific timeframe, emphasizing ease of use for DIY mechanics through detailed, illustrated steps and cost-saving repair guidance. Target Audience Target Audience: Enthusiasts, amateur mechanics, and professional technicians looking to service, maintain, or restore KTM 250, 400, 450, 520, and 525 SX, MXC, and EXC models from the 2000-2003 model years. 📋 Manual Details Coverage Areas Systems Covered: General Information, Periodic Maintenance, Engine, Fuel System, Cooling System, Electrical System, Chassis, Emission Control Information Procedures Included: Maintenance, Repair, Rebuild, Refurbishment, Restoration, Troubleshooting Page Count Page Count: Not specified, but described as 'comprehensive' and 'hundreds of photos and illustrations' Manual Type Manual Type Description: A highly detailed digital service repair manual designed for both DIY enthusiasts and experienced mechanics, providing step-by-step instructions for complete disassembly and repair procedures. Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine: Detailed information on engine disassembly, assembly, inspection, and repair for 250cc, 400cc, 450cc, 520cc, and 525cc variants. Likely includes top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), and associated components. Fuel System: Covers carburetor systems (likely Keihin or Mikuni for this era), fuel tank, fuel lines, and fuel pump operation (if applicable). Includes tuning and troubleshooting. Cooling System: Details on the liquid cooling system, including radiator, coolant hoses, water pump, thermostat, and coolant specifications. Maintenance and repair of leaks or blockages. Electrical System: Covers ignition system (CDI, spark plug), lighting, battery, charging system (stator, rectifier/regulator), starter motor (if applicable), and wiring diagrams. Troubleshooting electrical faults. Chassis: Includes frame inspection, front suspension (forks, triple clamps), rear suspension (shock absorber, linkage), steering system, wheel bearings, and brake systems (hydraulic disc brakes front and rear). Emission Control: Information related to emission control systems, likely focusing on carburetor adjustments and potentially any mandated evaporative emission controls for the period. May include air filter specifications. Frame And Bodywork: The manual would include procedures for inspecting, repairing, or replacing frame components, plastic body panels, seat, fuel tank, and handlebar assembly. It also covers swingarm and rear linkage maintenance. Wheel And Tire Service: Information on wheel bearing maintenance, spoke tensioning (if applicable), tire installation and removal, and recommended tire pressures for various riding conditions would be included. Suspension Service: Detailed procedures for servicing front forks (oil changes, seal replacement, spring inspection) and rear shock absorbers (rebuilding, nitrogen charging if applicable, linkage maintenance). Procedures Included Periodic Maintenance: Covers scheduled maintenance tasks such as oil changes, filter replacements, chain adjustment, brake fluid changes, coolant flushes, and valve clearance checks. Includes maintenance schedules. Repair Procedures: Provides detailed, step-by-step instructions for a wide range of repairs, from minor adjustments to complete engine and chassis overhauls, referencing complete disassembly. Troubleshooting Guide: The manual likely includes a dedicated troubleshooting section to help diagnose and resolve common problems based on symptoms, covering engine, electrical, and chassis issues. Component Rebuilds: Includes comprehensive instructions for rebuilding key components such as the engine (piston, rings, valves, crankshaft), carburetor, water pump, and brake calipers. Technical Depth Technical Depth: Extensive, covering everything from basic maintenance to in-depth engine rebuilds, component diagnostics, and troubleshooting of complex systems. Supports both routine upkeep and major repairs. Diagnostic Procedures: Detailed diagnostic steps for identifying faults within the engine (compression testing, spark plug analysis), fuel...