🏷️ Basic Information Identification Make: KTM Model: 450 EXC, 400 EXC, 520 SX Production Years: 2000, 2001, 2002, 2003 Codes Manual Identifier: Service Repair Manual PDF Download 👋 Introduction Market Position Target Audience: KTM owners and independent repair shops performing maintenance and repairs on 2000-2003 EXC and SX models Competitive Analysis Value Proposition: Provides comprehensive factory-level repair information at a fraction of the cost of dealership service or traditional print manuals, with the convenience of immediate download. Key Features Feature Set: Hundreds of pages, detailed illustrations and photos, step-by-step instructions, troubleshooting guide, electrical diagrams, printable format. 📋 Manual Details Coverage Areas Vehicle Models Covered: KTM 450 EXC, KTM 400 EXC, KTM 520 SX Model Years Covered: 2000, 2001, 2002, 2003 Page Count Estimated Pages: Hundreds (exact number not specified, but implies comprehensive coverage) Manual Type Type: Workshop Service Repair Manual Language Primary Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, troubleshooting Transmission: Gearbox overhaul, maintenance, troubleshooting Electrical System: Wiring diagrams, troubleshooting, component diagnosis, repair procedures Chassis: Frame, suspension (front and rear), steering system, wheels, tires Brakes: Hydraulic brake system service, maintenance, troubleshooting Fuel System: Carburetor service, fuel lines, fuel tank maintenance Cooling System: Radiator service, coolant, hose inspection Exhaust System: Exhaust component inspection and maintenance Bodywork: Body panels, seat, plastics inspection and minor repairs Procedures Included Maintenance: Regular service, lubrication, inspections, fluid changes Troubleshooting: Diagnostic steps for common and complex issues, electrical fault finding Repair: Step-by-step instructions for component removal, repair, and reinstallation Rebuilds: Complete disassembly and reassembly procedures for major components Adjustments: Carburetor tuning, suspension adjustments, clutch and throttle cable adjustments Technical Depth Depth: Complete factory service information, suitable for both DIY and professional mechanics Detail Level: Detailed substeps, notes, cautions, warnings, numbered instructions, and bold figure numbers 📊 Manual Specifications File Format Format: PDF Compatibility: Compatible with all PC-based Windows operating systems and Mac Print Quality Printability: Printable without any restriction, allows printing entire manual or specific pages Binding Type Binding: Digital Download (user can print and bind) Paper Type Digital Storage: Saves to hard-drive, can be burned to CD-ROM Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type General: Four-stroke, single-cylinder (specific engine code/designation not provided in product info, but typical for these models) Performance Displacement 400: Approx. 397cc (for 400 EXC) Displacement 450: Approx. 449cc (for 450 EXC) Displacement 520: Approx. 510cc (for 520 SX) Fuel System Fuel Delivery: Carburetor (specific model like Keihin or Mikuni would be detailed in the manual) Fuel Type: Unleaded gasoline (manual will specify octane rating) Lubrication Oil Type Specification: Manual will specify exact KTM-recommended oil viscosity and API classification (e.g., Motorex, SAE 10W/40 or 15W/50) Ignition Ignition System: CDI (Capacitor Discharge Ignition) with electronic advance (specifics in manual) 🔧 Transmission Standard Transmission Type: Manual 6-speed sequential gearbox Features Clutch Type: Hydraulically operated multi-plate wet clutch (manual details service and adjustment) Fluid Requirements Gear Oil Type: Manual will specify KTM-approved gearbox oil (e.g., Motorex Gear Oil 75W) 📐 Dimensions Weights Dry Weight Estimated: Approx. 110-120 kg (varies by model, specific figures in manual) Wet Weight Estimated: Approx. 120-130 kg (with fluids, varies by model) 🛡️ Safety Features Ratings Safety Standards: Not applicable for off-road motorcycles in terms of automotive crash ratings. Focus on component safety and operational integrity. Active Features Braking System: Hydraulic disc brakes front and rear (manual covers inspection, pad replacement, fluid bleeding). Suspension Stability: Adjustable suspension components (e.g., WP USD forks, WP PDS shock) for handling and stability (manual covers adjustment and service). 💡 Technology Features Infotainment Infotainment System: None (these are performance off-road motorcycles). Driver Assistance Assistance Features: None (these are performance off-road motorcycles). Connectivity Connectivity Features: None (these are performance off-road motorcycles). 🔧 Maintenance Service Intervals Oil Change Interval: Manual will specify intervals based on riding hours or mileage (e.g., every 10-20 operating hours for severe use). Air Filter Cleaning: Frequent cleaning and oiling recommended, especially in dusty conditions (details in manual). Spark Plug Replacement: Specific intervals based on plug type and usage, detailed in manual. Fluid Specifications Engine Oil Capacity: Manual will list exact oil capacity (e.g., 1.0 - 1.5 liters depending on model variant). Brake Fluid Type: DOT 4 or DOT 5.1 (manual will specify exact type and replacement interval). Coolant Type: Ethylene glycol-based coolant, typically a 50/50 mix with distilled water (manual will provide specific blend ratio and capacity). Known Issues Common Wear Items: Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings, chain and sprockets (manual provides inspection and replacement procedures). Carburetor Tuning Challenges: Altitude and temperature compensation adjustments may be required (manual offers guidance). 📚 Vehicle History Brand Heritage Brand Focus: KTM is renowned for its off-road racing heritage and high-performance motorcycles. Model Evolution Model Lineup: The EXC (Enduro) and SX (Motocross) lines represent KTM's dedicated...