KTM 450 EXC 400 EXC 520 SX 2000-2003 Factory Repair Manual

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Type: Motorcycle

Vendor:

Sku: 52437

Tags: 2000 2001 2002 2003 400 EXC 450 EXC 450 SX 520 SX ATV KTM Motorcycle Powersports

Product variants

Description

This manual provides comprehensive guidance for the 450 EXC, 400 EXC, and 520 SX models manufactured between 2000 and 2003. Renowned for its high-performance off-road motorcycles, these models were engineered for demanding terrain and competitive riding. The 450 EXC and 400 EXC are celebrated dual-sport/enduro machines, while the 520 SX is a potent motocross variant. These motorcycles are characterized by their robust construction, powerful single-cylinder four-stroke engines, and advanced suspension systems, embodying a commitment to quality and performance in the off-road segment. This factory service repair manual is an essential resource for owners, mechanics, and technicians. It offers factory-level detail covering all aspects of maintenance, repair, and diagnostics, including engine top-end procedures, fuel system servicing, clutch and lubrication systems, drivetrain maintenance, brake and suspension system overhauls, steering, frame inspection, and the complete electrical system. With hundreds of illustrations and detailed step-by-step instructions, this English-language manual enables efficient troubleshooting, routine maintenance, and component rebuilds, ultimately helping to preserve the performance and longevity of your motorcycle.

🏷️ Basic Information

Identification

Make:

Model:

450 EXC / 400 EXC / 520 SX

Product Name:

KTM 450 EXC 400 EXC 520 SX 2000-2003 Factory Repair Manual PDF Download

Codes

Product Code:

KTM-2000-2003-EXC-SX-RM-PDF

👋 Introduction

Market Position

Target Audience:

KTM owners, mechanics, and enthusiasts seeking to maintain and repair their 2000-2003 450 EXC, 400 EXC, and 520 SX models.

Value Proposition:

Provides factory-level expertise, enabling DIY maintenance and repairs, saving significant labor costs.

Competitive Analysis

Authenticity:

Actual Genuine Repair Service Factory Manuals, not third-party alternatives.

Key Features

Comprehensiveness:

Covers all aspects of maintenance, repair, and diagnostics for the specified models.

Usability:

Easy to navigate, print, and follow, even for those not highly computer-skilled.

Cost Savings:

Potential to save $50-$60 per hour on shop labor costs.

📋 Manual Details

Coverage Areas

Covered Years:

2000, 2001, 2002, 2003

Covered Models:

450 EXC, 400 EXC, 520 SX

Page Count

Estimated Pages:

Hundreds of pages (specific number not provided, but implied extensive)

Manual Type

Type:

Official Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Top End:

Detailed procedures for cylinder head, valves, piston, rings, camshafts.

Fuel System:

Carburetor settings, fuel pump, fuel lines, fuel tank inspection and repair.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, coolant specifications.

Clutch:

Clutch lever, cable adjustment, clutch plates, springs, pressure plates, clutch cover.

Engine Lubrication System:

Oil pump, oil filter, oil passages, oil level checks, oil type specifications.

Engine Removal Installation:

Step-by-step procedure for removing and reinstalling the engine assembly.

Crankshaft Transmission:

Crankshaft inspection, connecting rod, gearbox, gear shifting mechanisms, transmission bearings.

Wheels Tires:

Wheel bearing inspection, spoke tensioning, tire pressure recommendations, tire replacement.

Final Drive:

Chain maintenance, sprocket inspection, rear hub assembly.

Brakes:

Brake lever, pedal, brake calipers, master cylinders, brake fluid specifications, brake pad replacement, disc inspection.

Suspension:

Front fork (USD), rear shock absorber, suspension settings, seal replacement, oil levels.

Steering:

Handlebar, steering stem, steering head bearings, adjustment procedures.

Frame:

Frame inspection, welds, potential damage assessment.

Electrical System:

Ignition system, lighting, battery, wiring diagrams, troubleshooting electrical faults.

General Information:

Vehicle identification, torque specifications, maintenance overview, safety precautions.

Appendix:

Supplementary technical data, specifications, and charts.

Procedures Included

Maintenance:

Routine checks, lubrication, fluid changes, filter replacements, cable adjustments.

Troubleshooting:

Diagnostic guides for engine faults, electrical issues, and performance problems.

Repair:

Comprehensive step-by-step instructions for all major component repairs.

Rebuild:

Detailed procedures for engine and component rebuilds.

Tuning:

Carburetor tuning, ignition timing adjustments (where applicable).

Technical Depth

Depth:

Factory-level detail covering routine maintenance to complete engine and component overhauls.

Diagnostic Techniques:

Includes 'secret techniques' used by top mechanics for part testing and diagnosis.

Wiring Diagrams:

Detailed and traceable wiring diagrams for the entire electrical system.

Engine Management Systems:

Understanding and analysis of engine management systems (if applicable to these models).

Illustrations Diagrams:

Includes hundreds of illustrations, drawings, and photos to guide procedures.

Formatting Features:

Detailed substeps, notes, cautions, warnings, numbered instructions, bold figure numbers, enlarged insets.

📊 Manual Specifications

File Format

Format:

Accessibility:

Viewable and printable on PC (Windows) and Mac.

Searchability:

Searchable functionality for quick information retrieval.

Print Quality

Printability:

Printable without restriction (entire manual or specific pages).

Resolution:

High resolution

Binding Type

Delivery Method:

Digital Download

Physical Format:

Not applicable (digital delivery)

Paper Type

Storage Options:

Save to hard-drive, burn to CD-ROM.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke (typical for EXC/SX models of this era; specific details would be in the manual).

Engine Variants:

400cc, 450cc, 520cc (specific cubic capacities would be detailed within the manual).

Performance

Horsepower:

Specifications for each engine variant available in the manual.

Torque:

Specifications for each engine variant available in the manual.

Fuel System

Carburetion:

Details on the specific carburetor used (e.g., Keihin FCR, Mikuni) and its tuning.

🔧 Transmission

Standard

Transmission Type:

Manual, multi-gear (typical for these models, specific number of gears to be found in manual).

Optional

Optional Gearbox Ratios:

If different gearbox options or ratios were available, they would be detailed in the manual.

Features

Clutch Type:

Wet multi-plate clutch (standard for KTM off-road bikes of this period).

📐 Dimensions

Exterior

Body Style:

Dual-sport/Enduro/Motocross motorcycle.

Weights

Dry Weight:

Specifications for each model variant (e.g., 450 EXC, 520 SX) would be detailed in the manual.

Wet Weight:

Specifications for each model variant (e.g., 450 EXC, 520 SX) would be detailed in the manual.

🛡️ Safety Features

Ratings

Safety Features:

Focus on mechanical safety features such as reliable braking systems, robust frame construction.

Active Features

Braking System Type:

Hydraulic disc brakes front and rear (typical).

Passive Features

Frame Material:

Chromoly steel frame (typical for KTM off-road bikes).

💡 Technology Features

Infotainment

Features:

Primarily mechanical and electrical systems; no advanced infotainment features expected on these off-road models.

Driver Assistance

Features:

No electronic driver assistance systems typically found on these off-road oriented machines.

Connectivity

Features:

No wireless or integrated connectivity features expected.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Specific intervals for engine oil and filter changes detailed in the manual.

Valve Adjustment Interval:

Recommended intervals for valve clearance checks and adjustments provided.

Fluid Specifications

Engine Oil Type:

Specific SAE viscosity grade and API service classification for engine oil (e.g., Motorex Power Synt SAE 10W/50).

Coolant Type:

Recommended coolant mixture (e.g., 50/50 ethylene glycol and distilled water) and corrosion inhibitors.

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid specifications.

Known Issues

Common Wear Items:

The manual would likely highlight common wear items like brake pads, clutch plates, and chain/sprockets, with guidance on inspection and replacement.

Troubleshooting Tips:

The manual provides specific troubleshooting steps for common problems encountered with these models.

📚 Vehicle History

Brand Heritage

Manufacturer:

KTM AG, an Austrian manufacturer known for its off-road motorcycles.

Model Evolution

Generations Covered:

Manual covers specific models from the 2000-2003 model years, representing a particular generation of the EXC and SX lines.

Production

Production Period:

2000-2003 model years.

🏆 Awards & Recognition

Recognitions

Model Recognition:

KTM models from this era were generally well-regarded for their performance and off-road capabilities. Specific awards for these exact model years would need external research.

Ratings

Manual Quality:

Rated as a 'COMPLETE official full factory service repair manual' indicating high quality and comprehensive coverage.