This manual covers the SX, MXC, and EXC models manufactured between 2000 and 2003, featuring engine variants of 250cc, 400cc, 450cc, 520cc, and 525cc. These high-performance off-road motorcycles are renowned for their racing heritage and 'Ready to Race' philosophy, offering robust engineering and powerful performance characteristic of a commitment to off-road excellence. The models utilize four-stroke, single-cylinder engines, typically liquid-cooled, and are equipped with 5-speed manual transaxles and hydraulically actuated multi-plate wet clutches, providing a direct and responsive riding experience. This comprehensive workshop service repair manual provides detailed information for the maintenance, diagnosis, and repair of your motorcycle. It includes step-by-step instructions for engine mechanical and electrical systems, fuel systems, transmission, clutch, brakes, suspension, steering, and bodywork. The manual also covers scheduled maintenance, fluid specifications, troubleshooting guides, and wiring diagrams, making it an essential resource for both DIY enthusiasts and professional mechanics seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: KTM Model: SX, MXC, EXC Engine Variants: 250cc, 400cc, 450cc, 520cc, 525cc Production Years: 2000, 2001, 2002, 2003 👋 Introduction Market Position Segment: High-performance off-road motorcycles (Motocross, Enduro, Dual-Sport). Competitive Analysis Competitors: Yamaha YZ/WR series, Honda CR/CRF series, Suzuki RM/RM-Z series, Kawasaki KX/KDX series. Key Features Manual Features: Detailed illustrations, diagrams, wiring schematics, step-by-step instructions, troubleshooting guides, and specifications. Value Proposition Cost Savings: Inexpensive way to maintain and repair vehicles, avoiding costly dealership labor. 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive service and repair for KTM 250, 400, 450, 520, and 525 SX, MXC, and EXC models from 2000-2003. Page Count Estimated Page Count: Varies by specific model and engine size; typically 300-600+ pages for complete workshop manuals. Manual Type Type: Workshop Service Repair Manual / Factory Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed repair, overhaul, and component replacement procedures for all engine variants. Engine Electrical: Diagnosis, troubleshooting, and repair of the electrical system, including ignition and charging. Emission Control: Information related to emission control systems, if applicable to the target market/model year. Fuel System: Carburetor inspection, adjustment, and overhaul; fuel pump and line service. Suspension: Front fork and rear shock absorber service, seal replacement, and damping adjustments. Clutch: Clutch assembly inspection, adjustment, and replacement procedures. Transmission: Manual transaxle system repair, maintenance, and troubleshooting. Drivetrain: Driveshaft and axle inspection and service. Steering: Steering system maintenance and component replacement. Brakes: Hydraulic brake system inspection, bleeding, pad replacement, and caliper service. Body Interior Exterior: Fairing, seat, and other bodywork component service. Body Electrical: Wiring diagrams and troubleshooting for auxiliary electrical systems. Restraints: Information on seat belts and other restraint systems, if applicable. Procedures Included Maintenance: Scheduled maintenance, fluid changes, lubrication, and general upkeep. Troubleshooting: Diagnostic guides for identifying and resolving common and uncommon problems. Repair: Step-by-step instructions for component disassembly, repair, reassembly, and adjustment. Diagnostics: Detailed diagnostic procedures for all major systems. Wiring Diagrams: Comprehensive wiring schematics for electrical system troubleshooting and repair. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and chassis rebuilds. Target Audience: Suitable for both DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Format File Type: PDF Software Requirements: Adobe Acrobat Reader Print Quality Printability: Fully printable Zoom Capability: YES (Zoom IN/OUT enabled) Binding Type Binding: Digital (PDF download) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder (typical for this era of KTM off-road). Displacement Options: 250cc, 400cc, 450cc, 520cc, 525cc Performance Horsepower Torque: Specific figures vary significantly by displacement; manual provides detailed specifications for each model. Fuel System Carburetion: Mikuni or Keihin carburetors common for this period. Cooling System Cooling Method: Liquid-cooled (typical for performance KTMs of this era). 🔧 Transmission Standard Type: 5-speed manual transaxle (standard for SX, MXC, EXC). Optional Optional Types: N/A (Manual transmission standard). Features Gear Ratios: Specific gear ratios detailed within the manual for each model variant. Clutch Type: Hydraulically actuated multi-plate wet clutch. 📐 Dimensions Exterior General Dimensions: Dimensions vary by model; manual provides detailed specs for each. Weights Dry Weight: Varies by model and displacement (e.g., approximate dry weight range from ~230-250 lbs). Wet Weight: Varies by model and fluid capacities. 🛡️ Safety Features Ratings Safety Certifications: Off-road motorcycles typically not rated by NHTSA; compliance with local regulations is expected. Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Frame Construction: Chromium-molybdenum steel trellis frame. 💡 Technology Features Infotainment Display Systems: Basic digital or analog instrument clusters showing speed, RPM, and basic warning lights. Driver Assistance Electronic Aids: Primarily mechanical systems; no advanced electronic rider aids like ABS or traction control on these models. Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10-15 hours of riding, or as specified in the manual. Air Filter Cleaning: Frequent cleaning recommended, especially in dusty...