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KTM 400 EXC RACING 2000 - User Manual

KTM 400 EXC RACING 2000
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OWNERS HANDBOOK
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
2000
400/520 SX, EXC RACING
BEDIENUNGSANLEITUNG
Art.Nr. 3.205.72 11/99

Table of Contents

Questions and Answers

  • K
    knoxvictoriaAug 19, 2025
    What to do if KTM Motorcycle engine gets too hot?
    • M
      Matthew GibsonAug 20, 2025
      If your KTM Motorcycle engine is overheating, there are several potential causes to investigate. First, check the cooling liquid level and refill if it's insufficient, also inspect the cooling system for any leaks. Ensure there's enough air stream by driving briskly. If the cooling system hasn't been bled, bleed it. Clean the radiators with a water jet if they are very dirty. Replace the cooling liquid if there's foam formation, and use antifreeze liquid with a brand name. Inspect the cooling hoses for bends and either shorten or replace them. Finally, check the thermostat for defects by dismounting it and verifying its opening temperature (70°C / 158°F), or replace it if necessary.
  • R
    Robert SmithAug 22, 2025
    How to fix a KTM Motorcycle that doesn’t crank?
    • S
      Sandra StrongAug 22, 2025
      If your KTM Motorcycle engine isn’t cranking, start by checking for an operating error, such as ensuring the emergency-OFF switch is turned on (Australia only). If that's not the issue, a blown fuse could be the culprit; dismount the left paneling and the filter box cover to replace the fuse in the starter relay. A discharged battery can also prevent cranking, so recharge the battery and investigate the causes for discharging.
  • M
    Mariah SimpsonAug 25, 2025
    What causes KTM Motorcycle engine not reaching full power?
    • A
      aaron49Aug 26, 2025
      Several factors can cause a KTM Motorcycle engine to not reach full power. These include a partially interrupted fuel supply or a dirty carburetor, a leaking float, a very dirty air filter, a damaged or non-tight exhaust system, a valve gap that is too small, loss of compression, or faulty electronical ignition timing. Clean and check the fuel system and carburetor, replace the float, clean or replace the air filter, check the exhaust system, adjust the valve gap, check the setting of the hand decompression cable, or have the ignition system checked.
  • M
    Mr. Bryan BrownAug 27, 2025
    Why KTM 400 EXC RACING 2000 engine fails to idle?
    • A
      Amanda BrewerAug 28, 2025
      A KTM Motorcycle engine may fail to idle for several reasons. The idling jet might be clogged, which requires disassembling the carburetor and cleaning the jets. The adjusting screws on the carburetor might be incorrectly adjusted, necessitating a carburetor adjustment. A defective spark plug can also cause idling issues, so replace the spark plug. Lastly, a defective ignition system could be the problem, in which case you should have the ignition system checked.
  • W
    whitekristopherAug 30, 2025
    Why is my KTM 400 EXC RACING 2000 battery discharged?
    • G
      Gary WongAug 30, 2025
      The KTM Motorcycle battery may be discharged because it isn’t being charged by the generator. Remove the seat and fuel tank and check voltage regulator connections. A KTM dealer should check the voltage regulator and generator.
  • S
    Susan LesterSep 2, 2025
    What to do if horn, flasher lights, and E-starter do not work on KTM 400 EXC RACING 2000?
    • J
      Jillian MoralesSep 2, 2025
      If the horn, flasher lights, and E-starter on your KTM Motorcycle are not working, the cause may be a blown fuse in the starter relay. To address this, dismount the left side paneling and filter box cover, then replace the fuse.
  • D
    Dorothy CampbellSep 5, 2025
    What causes KTM 400 EXC RACING 2000 engine to stop or sputter in the carburetor?
    • L
      lanerebeccaSep 5, 2025
      If your KTM Motorcycle engine stops or sputters in the carburetor, it could be due to insufficient fuel. In this case, clean and check the fuel system and carburetor. Another possibility is that the engine is taking in air uncontrollably. Check the rubber sleeve and carburetor for a tight fit.
  • J
    Jeffrey BurchSep 8, 2025
    What to do if KTM 400 EXC RACING 2000 engine does not rev high?
    • L
      Lisa FlemingSep 8, 2025
      If your KTM Motorcycle engine does not rev high, it could be due to a few reasons. The carburetor fuel level may be too high because the float needle valve is dirty or worn out; therefore, dismount the carburetor and check if it's worn out. Another cause could be loose carburetor jets, which you should tighten. Finally, faulty electronical ignition timing could be the issue, requiring you to have the ignition system checked.
  • P
    paulphillipsSep 10, 2025
    What causes high oil consumption in KTM Motorcycle?
    • E
      Elizabeth SullivanSep 12, 2025
      High oil consumption in your KTM Motorcycle can be attributed to several factors. The hose of the engine ventilation might be bent, so dislocate or replace it with a non-buckling ventilation hose. The engine oil level may be too high, requiring you to check and correct it if necessary. Additionally, the motor oil might be too thin (low viscosity); in this case, use a thicker engine oil.
  • U
    ugarciaSep 13, 2025
    Why all switched on lamps blown out on KTM 400 EXC RACING 2000?
    • R
      raymondtorresSep 13, 2025
      If all the switched-on lamps in your KTM Motorcycle have blown out, the capacitor or voltage regulator may be faulty. To address this, dismount the seat and fuel tank and check the connections. Have the capacitor and voltage regulator checked.

Summary

Introduction

Serial Number Locations

Identification of chassis and engine numbers for motorcycle registration.

Clutch Lever Operation

Description and adjustment of the motorcycle's clutch lever.

Decompression Lever Operation

Function and operation of the hand decompression lever.

Front Brake Lever Adjustment

Location and adjustment of the front wheel brake lever.

Operation Instruments and Controls

EXC Digital Speedometer and Indicators

Explanation of the digital display and indicator lights on EXC models.

Handlebar Controls and Switches

Operation of the combination switch, headlamp, and flasher switches.

Fuel System Operation

Operation of the filler cap, fuel tap, and fuel level management.

Riding and Driving Instructions

Pre-Ride Inspection Checklist

Essential checks before starting the motorcycle for safety.

Initial Operation and Engine Break-in

Guidance for first rides and the break-in procedure for racing models.

Riding and Shifting Techniques

Instructions on shifting, riding, and throttle control.

Braking, Stopping, and Parking

Safe braking techniques and procedures for stopping and parking.

Motorcycle Maintenance Procedures

Chassis Adjustments and Checks

Adjusting clutch lever, steering head bearings, and handlebar position.

Brake System Maintenance

Information on disc brakes, fluid levels, pads, and levers.

Wheel and Tire Service

Procedures for wheel removal/installation and tire/spoke checks.

Battery Care and Charging

Battery maintenance and charging procedures for the motorcycle battery.

Cooling System Service

Procedures for checking coolant level and bleeding the system.

Engine Oil and Carburetor Service

Adjusting cables, clutch oil, carburetor, and engine oil changes.

Cleaning and Storage

Winter Riding and Conservation

Protecting the motorcycle from salt and weather during winter.

Motorcycle Storage Guidelines

Instructions for preparing the motorcycle for long-term storage.

Technical Specifications

Engine Technical Data

Detailed technical data for the motorcycle's engine.

Tightening Torques

List of torque specifications for various fasteners and components.

Chassis Technical Data

Detailed technical data for the motorcycle's chassis and suspension.

Wiring Diagram

Wiring Diagram Component List

Lists of electrical components in multiple languages for the wiring diagram.

KTM 400 EXC RACING 2000 Specifications

General IconGeneral
BrandKTM
Model400 EXC RACING 2000
CategoryMotorcycle
LanguageEnglish

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