This manual covers the 450 EXC, 400 EXC, and 520 SX models from the 2000 to 2003 model years. These motorcycles are renowned for their high-performance, off-road capabilities, featuring powerful four-stroke engines, agile chassis, and sophisticated suspension systems. Built with Austrian engineering heritage, these bikes were designed for serious enduro and motocross riders, offering exceptional handling and durability in demanding terrain. Their competitive edge is further underscored by their success in various off-road racing disciplines. This comprehensive factory service repair workshop manual provides detailed information essential for the maintenance, troubleshooting, and repair of your motorcycle. It covers all major systems, including the engine, transmission, chassis, brakes, and electrical components, with step-by-step procedures for everything from routine servicing and component replacement to complete engine and suspension rebuilds. The manual includes critical technical specifications, torque values, wiring diagrams, and diagnostic guidance to ensure your vehicle remains in optimal condition and performs at its best. 🏷️ Basic Information Identification Make: KTM Model: 450 EXC / 400 EXC / 520 SX Model Codes: Not explicitly provided in product data, but typically internal KTM codes would exist for each variant. Generation Generation Covered: First Generation (or early generation) covering the 2000-2003 model years. Codes Vin Decoding Info: Manual is expected to contain information or references to VIN decoding for model year identification and specific component sourcing. 👋 Introduction Market Position Positioning: These KTM EXC and SX models were positioned as high-performance, off-road motorcycles, targeting serious enduro and motocross riders. Known for their powerful engines and agile handling. Competitive Analysis Competitors: Competed against other European and Japanese manufacturers in the off-road segment, such as Husqvarna, Yamaha YZ-F, Honda CR-FX, Suzuki RM-Z, and Kawasaki KX-F models of the era. Key Features Features: Strong, torquey engines, sophisticated suspension, lightweight chassis, and performance-oriented design. Popular for their off-road prowess and adaptability for dual-sport conversions. Manual Value Value Proposition: Provides essential factory information for owners and technicians to maintain, troubleshoot, and repair these specialized off-road machines, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Vehicle Years: 2000, 2001, 2002, 2003 Vehicle Models: KTM 450 EXC, KTM 400 EXC, KTM 520 SX Page Count Page Count: Not explicitly stated, but typically factory service manuals for this era are extensive, often 400-800+ pages. Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English (standard for factory manuals unless otherwise specified). Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, diagnosis, and repair for all specified models. Includes carburetor tuning, ignition system, cooling system (if applicable, though these are often air-cooled), and lubrication. Transmission: Clutch operation and adjustment, gearbox inspection, repair, and maintenance. Includes gear shift mechanism and related components. Chassis: Frame inspection and repair, suspension (forks, shock absorber) service, adjustment, and overhaul. Includes linkage systems. Wheel bearing and hub service. Brakes: Hydraulic brake system diagnosis, bleeding, caliper and master cylinder service, pad replacement, and disc inspection. Electrical: Wiring diagrams, troubleshooting common electrical faults, lighting system, ignition system components, battery maintenance, and charging system. Fuel System: Carburetor identification, disassembly, cleaning, rebuilding, and adjustment. Fuel tank inspection and maintenance. Cooling System: While primarily air-cooled, any oil cooling or related components will be covered. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, valve clearance checks, spark plug replacement. Troubleshooting: Diagnostic procedures for common performance issues, starting problems, running issues, and electrical faults with symptom-based guides. Repair: Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly for all major vehicle systems. Rebuilds: Detailed procedures for engine rebuilds, gearbox overhauls, and suspension component rebuilding. Specifications: Torque specifications for all fasteners, critical clearances, measurements, and tolerances. Technical Depth Depth: Comprehensive factory-level detail covering routine maintenance to complete engine and chassis overhauls. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF, allowing quick access to information. Print Quality Print Quality: High-resolution scans, suitable for printing clear diagrams and text. Binding Type Binding Type: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder Displacement 400: Approximately 373cc (for the 400 EXC) Displacement 450: Approximately 449cc (for the 450 EXC) Displacement 520: Approximately 498cc (for the 520 SX) Bore X Stroke 400: Specifics vary by exact model, but typical for this era would be around 84.5 mm x 66 mm. Bore X Stroke 450: Specifics vary by exact model, but typical for this era would be around 95 mm x 63.4 mm. Bore X Stroke 520: Specifics vary by exact model, but typical for this era would be around 97 mm x 64.7 mm. Cooling System: Air-cooled (typically for these models, but manual will confirm any oil cooling provisions). Valvetrain: SOHC, 4 valves per cylinder Performance Horsepower 400: Estimated 45-50 HP (at crankshaft,...