This manual covers SX, MXC, and EXC Racing series motorcycles from the 2000-2003 model years, equipped with 4-stroke engines. These high-performance off-road motorcycles are renowned for their advanced chassis technology and 'Ready to Race' philosophy, making them a dominant force in motocross, enduro, and cross-country competition. The SX models are purpose-built for motocross, the MXC variants are designed for cross-country events, and the EXC models offer enduro capabilities, often including street-legal features for versatility. With their agile handling and powerful engines, these motorcycles are favored by enthusiasts and professional racers alike for their reliability and competitive edge. This comprehensive Workshop Service Repair Manual provides essential technical data and step-by-step instructions for maintaining and repairing your motorcycle. It covers all major systems, including the engine, transmission, chassis, electrical components, and braking system, detailing everything from routine maintenance, oil changes, and filter replacements to complete engine overhauls and component rebuilds. The manual also includes troubleshooting guidance for common issues, ensuring that owners, mechanics, and technicians can efficiently diagnose and resolve problems, optimize performance, and extend the lifespan of their vehicle. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Racing Engine Type: 4-Stroke Applicable Years: 2000, 2001, 2002, 2003 Codes Motorcycle Segment: Off-Road / Dual-Sport / Motocross / Enduro 👋 Introduction Market Position Segment: High-performance off-road motorcycles. Target Audience: Motocross, enduro, and off-road enthusiasts, mechanics, and service centers. Competitive Analysis Competitors: Yamaha YZ/WR series, Honda CRF/XR series, Suzuki RM/DR series, Kawasaki KX/KLX series. Key Features Manufacturer Focus: KTM is renowned for its 'Ready to Race' philosophy, emphasizing performance and advanced chassis technology. Manual Value Proposition: Provides essential technical data for DIY maintenance, repairs, and performance tuning, saving on professional service costs. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Page Count Estimated Page Count: 300-500 (typical for this era and model complexity) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor), ignition system. Transmission: Gearbox operation, inspection, repair, clutch service, maintenance. Chassis: Frame inspection, suspension (forks, rear shock), steering system, wheel bearings, swingarm. Electrical: Wiring diagrams, lighting system, ignition coil, stator, battery maintenance, starter system (if applicable). Braking System: Hydraulic brake system (front and rear), caliper service, pad replacement, fluid bleeding, rotor inspection. Fuel System: Carburetor identification, disassembly, cleaning, adjustment, jetting, fuel tank, petcock. Exhaust System: Muffler, header pipe inspection and maintenance. Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks. Troubleshooting: Common problems, diagnostic procedures for engine performance, electrical issues, starting problems. Repair: Step-by-step instructions for component disassembly, repair, and reassembly. Rebuilds: Detailed procedures for engine top-end rebuilds, carburetor rebuilds. Technical Depth Depth: Comprehensive, covering everything from basic scheduled maintenance to complete engine and component overhauls. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text enabled for quick information retrieval. Printability: Printable pages for physical reference. Print Quality Image Resolution: High-resolution, clear illustrations and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Configuration: Single-cylinder, 4-stroke Engine Configuration Bore X Stroke 250: Approx. 76 mm x 54.8 mm Bore X Stroke 400: Approx. 87 mm x 65.5 mm Bore X Stroke 450: Approx. 95 mm x 63.4 mm Bore X Stroke 520/525: Approx. 95 mm x 72 mm (525cc variant) Performance Horsepower Range: Estimated 40-55+ HP (depending on displacement and model variant) Torque Range: Estimated 35-45+ Nm (depending on displacement and model variant) Fuel System Carburetor Type: Keihin FCR (Flat CR) Carburetor Sizes: Typically 39mm or 41mm FCR Cooling System Type: Liquid-cooled Lubrication Oil Type Specification: SAE 10W-40 or 15W-50 semi-synthetic or fully synthetic motorcycle oil, API SG or higher. Valve Train Configuration: DOHC (Double Overhead Camshaft), 4 valves per cylinder 🔧 Transmission Standard Type: Constant mesh, 5-speed Features Clutch Type: Wet, multi-plate, hydraulically operated Fluid Specifications Transmission Oil Type: Dedicated transmission oil or engine oil meeting specific viscosity and API rating (refer to manual for exact specs). 📐 Dimensions Exterior General Classification: Compact, agile off-road motorcycle chassis. Weights Dry Weight Range: Approx. 105-115 kg (depending on model and displacement) Wet Weight Estimate: Approx. 115-125 kg (with fluids) 🛡️ Safety Features Ratings Safety Standards: Designed for off-road competition and recreational use; not typically subject to road-legal safety ratings. Active Features Braking Performance: High-performance hydraulic disc brakes (front and rear) for reliable stopping power. Passive Features Chassis Design: Strong, lightweight chromoly steel frame provides rigidity and impact absorption. 💡 Technology Features Infotainment Features: Minimal to no electronic infotainment features; focus is on performance and rider engagement. Driver Assistance Features: No electronic driver assistance features (e.g., ABS, traction control) on standard models of this era. Connectivity Features: No electronic connectivity features. 🔧 Maintenance Service Intervals...