Target Audience:
KTM owners and independent repair shops performing maintenance and repairs on 2000-2003 EXC and SX models
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.
Feature Set:
Hundreds of pages, detailed illustrations and photos, step-by-step instructions, troubleshooting guide, electrical diagrams, printable format.
Vehicle Models Covered:
KTM 450 EXC, KTM 400 EXC, KTM 520 SX
Model Years Covered:
2000, 2001, 2002, 2003
Estimated Pages:
Hundreds (exact number not specified, but implies comprehensive coverage)
Type:
Workshop Service Repair Manual
Primary Language:
English
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
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
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
Compatibility:
Compatible with all PC-based Windows operating systems and Mac
Printability:
Printable without any restriction, allows printing entire manual or specific pages
Binding:
Digital Download (user can print and bind)
Digital Storage:
Saves to hard-drive, can be burned to CD-ROM
Software Requirements:
Adobe PDF Reader
Engine Type General:
Four-stroke, single-cylinder (specific engine code/designation not provided in product info, but typical for these models)
Displacement 400:
Approx. 397cc (for 400 EXC)
Displacement 450:
Approx. 449cc (for 450 EXC)
Displacement 520:
Approx. 510cc (for 520 SX)
Fuel Delivery:
Carburetor (specific model like Keihin or Mikuni would be detailed in the manual)
Fuel Type:
Unleaded gasoline (manual will specify octane rating)
Oil Type Specification:
Manual will specify exact KTM-recommended oil viscosity and API classification (e.g., Motorex, SAE 10W/40 or 15W/50)
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic advance (specifics in manual)
Safety Standards:
Not applicable for off-road motorcycles in terms of automotive crash ratings. Focus on component safety and operational integrity.
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).
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.
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).
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).
Brand Focus:
KTM is renowned for its off-road racing heritage and high-performance motorcycles.
Model Lineup:
The EXC (Enduro) and SX (Motocross) lines represent KTM's dedicated off-road offerings. These models are characterized by robust engines, long-travel suspension, and lightweight chassis.
Manufacturing Location:
Austria (typical for KTM)
