This workshop service manual is designed for the KTM 520 SX for the years 2000, 2001, 2002, and 2003. It is intended for use by mechanical technicians familiar with service procedures for BRP products and covers repair and overhaul of the KTM 520 SX. The manual assumes the technician is well-versed in general automobile practices and emphasizes the special aspects of the product to enable the provision of quality service.
It includes instructions on components manufactured for the KTM 520 SX and incorporates instructions from respective component manufacturers for proprietary components. The manual aims to provide reliable information and procedures for routine maintenance, servicing, diagnostic, and repair procedures.
Whether for professional mechanics or DIY enthusiasts, this manual can be a cost-effective and informative resource for maintaining and repairing the KTM 520 SX. It is essential to observe safety precautions and use the recommended safety equipment and tools, including a torque wrench for fastener tightening according to specifications.
The manual contains specifications and procedures available in an authorized KTM 520 SX dealer service department and is a comprehensive guide for tune-ups, maintenance, removal/install procedures, assemblies/disassemblies, fuel system, ignition, lubrication system, exhaust, electrical system, and more.
It is important to note that this is an electronic delivery via email and is available in English. The content of the manual depicts parts and procedures applicable to the particular product at the time of writing.
General Information
Maintenance
Lubrication
Heating
Ventilation
Air Conditioning
Suspension
Front Suspension
Rear Suspension
Wheel
Tire System
Differential
Driveline
Drive Shaft
Transfer Case
Brakes
Engine
Engine Mechanical
Engine Cooling
Engine Fuel
Engine Electrical
Ignition System
Starting
Charging System
Emissions
Engine Exhaust
Engine Lubrication
Engine Speed Control System
Clutch
Cooling
Electronic Control Modules
Engine Systems
Heated Systems
Horn
Ignition Control
Instrument Cluster
Lamps
Power Systems
Restraints
Speed Control
Transmission
Exhaust System
Body Structure
Seats
Security and Locks
Air Bag System
Exterior Trim
Interior Trim
Frame
Bumpers
Fuel System
Steering
Transmission and Transfer Case
Tires
Wheels
Body
Heating
Air Conditioning
Emissions Control
Engine Removal
Engine Installation
Final Drive
Electrical System
Air cleaner element renewal
Air cleaner temperature control check
Auxiliary drivebelt check
Battery electrolyte level check
Battery terminal check
Brake hydraulic fluid renewal
Brake hydraulic system seal and hose renewal
Brake pipe and hose check
Choke adjustment check
Contact breaker point renewal and distributor lubrication
