🏷️ Basic Information

Make:

KTM

Model:

400-520-SC-EXC Racing

Model Variants:

400 Racing, 520 Racing, SC (Sport Competition)

Generation Focus:

Likely covers the late 1990s to early 2000s era for these specific engine displacements and model designations.

Language:

DE (Deutsch)

👋 Introduction

Segment:

High-performance off-road competition motorcycles (Enduro and Motocross/Supercross variants implied by SC).

Target Audience:

Enthusiast riders, amateur racers, professional mechanics, and KTM dealerships.

Competitors:

During their production era, these models competed with similar displacement offerings from brands like Husqvarna, Honda (CRF series), Yamaha (YZF series), Suzuki (RM series), and Kawasaki (KX series).

Performance Orientation:

These models were engineered for maximum performance and durability in demanding off-road conditions. Known for potent engines and advanced suspension for their time.

Kpm Philosophy:

Reflects KTM's 'Ready to Race' philosophy, focusing on delivering competitive machines straight from the factory with minimal modifications needed for racing.

📋 Manual Details

Systems Covered:

Engine (400cc & 520cc variants), Chassis, Suspension (Front & Rear), Brakes, Electrical System, Fuel System, Exhaust System, Cooling System, Drivetrain (Transmission & Clutch), Wheel & Tire Specifications, Bodywork, Troubleshooting, Routine Maintenance.

Page Count:

103

Manual Type:

Service Manual / Repair Manual / Anwenderhandbuch (User Manual)

Language:

German

Format:

.pdf

📖 Manual Coverage

Engine Systems:

Detailed breakdown of 4-stroke engine components, including cylinder head, piston, crankshaft, connecting rod, valve train (timing chain, camshafts, valves), lubrication system (oil pump, oil filter, oil passages), cooling system (radiator, water pump, hoses), ignition system (spark plug, coil, CDI unit), and starting system (kickstarter mechanism, decompression mechanism).

Transmission And Drivetrain:

Inspection, maintenance, and repair procedures for the gearbox (gear selection, shifting mechanisms), clutch system (clutch plates, springs, actuation), final drive (chain and sprockets), and associated bearings and seals.

Chassis And Suspension:

Information on frame integrity, steering head bearings, fork (Öhlins or WP depending on variant), rear shock absorber (Öhlins or WP depending on variant), linkage systems, swingarm, and wheel bearings. Includes adjustments and service procedures.

Braking System:

Front and rear brake systems (likely Brembo), including caliper maintenance, master cylinder service, brake fluid replacement, pad inspection and replacement, disc inspection, and bleeding procedures.

Electrical System:

Wiring diagrams, component identification (lights, horn, indicators, CDI unit, stator, regulator/rectifier), battery maintenance, fuse inspection, and troubleshooting common electrical faults.

Fuel And Exhaust:

Carburetor (likely Keihin or Mikuni) settings, cleaning, and overhaul. Fuel tank, fuel lines, and fuel filter maintenance. Exhaust system inspection and common repair points.

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug inspection and replacement, valve clearance checks, tire pressure checks, and general bolt torque verification.

Engine Rebuild:

Detailed instructions for engine disassembly, component inspection (piston rings, cylinder bore, valve seats, bearings), reassembly with specified torque values, and break-in procedures.

Troubleshooting:

Diagnostic tables and common problem-solving guides for engine starting issues, performance problems, electrical faults, and suspension performance. Includes potential causes and corrective actions.

Suspension Service:

Fork seal replacement, fork oil changes and level adjustments, rear shock absorber service and nitrogen charging (if applicable), and linkage bearing service.

Carburetor Tuning:

Guidance on jetting, needle position, idle speed adjustment, and float level settings for optimal performance in various conditions.

Depth Level:

Comprehensive. Covers from basic rider-level checks and adjustments to in-depth mechanical repairs and engine overhauls. Suitable for both home mechanics and professional workshops.

Diagnostic Capability:

Enables diagnosis of mechanical, electrical, and performance-related issues through structured troubleshooting steps and reference data.

Rebuild Capability:

Provides detailed instructions and specifications for complete engine and component rebuilds, including tolerances and part clearances.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely searchable text within the PDF, assuming it's not a scanned image without OCR.

Print Quality Assessment:

Assumed good quality for a digital manual; clarity of diagrams and text is crucial for usability.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Type:

4-Stroke, Single Cylinder

Engine Codes:

Specific engine codes would vary by year and exact model (e.g., LC4 series derivatives common in this era).

Bore X Stroke 400:

Typical for a 400cc: Approx. 88 mm x 63.6 mm

Bore X Stroke 520:

Typical for a 520cc: Approx. 95 mm x 72.2 mm

Displacement 400:

Approx. 373cc - 400cc (depending on specific tuning/model variation)

Displacement 520:

Approx. 477cc - 520cc (depending on specific tuning/model variation)

Cooling System:

Liquid-Cooled

Valve Train:

SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific model year and variant. Typically 4 valves.

Horsepower 400:

Estimated 40-50 HP (at crankshaft, depending on tune and year)

Horsepower 520:

Estimated 50-60 HP (at crankshaft, depending on tune and year)

Torque 400:

Estimated 35-45 Nm

Torque 520:

Estimated 45-55 Nm

Fuel Delivery:

Carburetor (e.g., Keihin PWK or Mikuni TM series)

Fuel Type:

Unleaded Gasoline (Premium Recommended)

Fuel Tank Capacity:

Typically 7-10 liters (depending on specific model and fuel tank fitted)

🔧 Transmission

Transmission Type:

5-Speed Manual

Optional Transmissions:

N/A (These were typically offered with a standard 5-speed manual)

Clutch Type:

Wet Multi-Plate Clutch (Hydraulically Actuated)

Gear Ratios:

Specific gear ratios are detailed within the manual, crucial for understanding power delivery across the rev range.

📐 Dimensions

Dimensions Overview:

Specific dimensions (length, width, height) vary significantly by year and model. The manual will provide exact measurements for frame and bodywork components.

Dry Weight:

Typically in the range of 110-130 kg (dry, depending on model variant and equipment)

Wet Weight:

Estimated 120-140 kg (with all fluids, depending on model variant)

🛡️ Safety Features

Safety Ratings:

N/A (Off-road competition motorcycles are not typically subjected to standard automotive safety crash testing and ratings).

Active Safety:

Primarily relies on rider skill, high-performance braking systems, and stable chassis dynamics. No electronic rider aids like ABS or traction control were standard on these models.

Passive Safety:

Sturdy frame construction, protective bodywork. The manual emphasizes proper maintenance of critical components like brakes and suspension for operational safety.

💡 Technology Features

Infotainment Features:

N/A (These are pure off-road competition motorcycles with no infotainment features like touchscreens or audio systems).

Driver Assistance Features:

N/A (No electronic driver assistance systems are present).

Engine Management System:

CDI (Capacitor Discharge Ignition) system. The manual covers its components and basic troubleshooting.

🔧 Maintenance

Oil Change Interval:

Typically every 15-20 hours of riding or annually, whichever comes first (detailed in manual).

Air Filter Cleaning:

Recommended after every few rides, or more frequently in dusty conditions (detailed in manual).

Valve Clearance Check:

Typically every 50-100 hours of riding or annually, depending on usage (detailed in manual).

Chain And Sprockets:

Regular cleaning, lubrication, and adjustment; replacement based on wear indicators (detailed in manual).

Engine Oil Type:

High-quality motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 or 10W-50, meeting JASO MA/MA2 standards (exact specification in manual).

Engine Oil Capacity:

Approx. 1.2 - 1.5 liters (with filter change, exact amount in manual).

Coolant Type:

Ethylene Glycol based antifreeze mixture (e.g., Motorex Coolant M3.0 or equivalent, 50/50 mix with distilled water) (exact specification in manual).

Brake Fluid Type:

DOT 4 or DOT 5.1 brake fluid (consult manual for specific recommendation, typically DOT 4).

Clutch Fluid Type:

Mineral oil (e.g., Magura Blood) for hydraulic clutch systems (if applicable) or DOT 4 for others (consult manual).

Common Wear Items:

Clutch plates, piston rings, valve guides, wheel bearings, and steering head bearings are common wear items due to high-performance use. The manual addresses their inspection and replacement.

Carburetor Issues:

Carburetor jets can become clogged with fuel varnish if the bike sits for extended periods. The manual provides cleaning and rebuilding procedures.

Suspension Leaks:

Fork seals and rear shock seals can wear, leading to oil leaks. Routine service outlined in the manual helps prevent this.

📚 Vehicle History

Ktm Offroad Focus:

KTM has a long and successful history in off-road motorsports, particularly in motocross, enduro, and rallies, establishing a reputation for ruggedness and performance.

Lc4 Lineage:

These models are part of KTM's renowned LC4 engine family, known for their torque and versatility in off-road applications. The SC designation typically points to a more track-focused or competition-oriented variant.

Production Era:

Likely produced between the late 1990s and mid-2000s. The manual would cover specific model years within this range.

Manufacturing Location:

Austria (KTM's primary manufacturing base)

🏆 Awards & Recognition

Motorsport Success:

KTM models of this era achieved significant success in various off-road racing disciplines. While not specific to these exact models, they contributed to KTM's overall racing pedigree.

Industry Perception:

Highly regarded in the off-road community for their performance, build quality, and durability when properly maintained.