KTM 520 EXC RACING 2000 User Manual (English)

Questions and Answers:

R
Rebecca HarrisonAug 20, 2025
What to do if KTM 520 EXC RACING 2000 engine gets too hot?
- M
  morandanielleAug 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.
T
tiffanymaldonadoAug 22, 2025
How to fix a KTM 520 EXC RACING 2000 Motorcycle that doesn’t crank?
- A
  Alicia HooverAug 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.
J
Joseph MckayAug 26, 2025
What causes KTM Motorcycle engine not reaching full power?
- E
  erika88Aug 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.
V
Valerie StewartAug 28, 2025
Why KTM 520 EXC RACING 2000 Motorcycle engine fails to idle?
- T
  Thomas CardenasAug 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.
T
Tammy MorrisonAug 30, 2025
Why is my KTM 520 EXC RACING 2000 Motorcycle battery discharged?
- C
  christian27Aug 31, 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.
D
Daniel HughesSep 2, 2025
What to do if horn, flasher lights, and E-starter do not work on KTM Motorcycle?
- D
  Danielle ElliottSep 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.
A
Andrew WallsSep 5, 2025
What causes KTM 520 EXC RACING 2000 Motorcycle engine to stop or sputter in the carburetor?
- E
  Erin NealSep 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.
K
Kevin RamirezSep 7, 2025
What to do if KTM 520 EXC RACING 2000 Motorcycle engine does not rev high?
- J
  Jessica WilkinsSep 7, 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.
B
Bethany BowmanSep 12, 2025
What causes high oil consumption in KTM Motorcycle?
- G
  Gabrielle MeyerSep 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.
S
Stephen AustinSep 13, 2025
Why all switched on lamps blown out on KTM Motorcycle?
- S
  Sheila BrooksSep 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.

KTM 520 EXC RACING 2000 Specifications

General

Year	2000
Manufacturer	KTM
Model	520 EXC RACING
Engine Type	Single cylinder, 4-stroke
Displacement	510 cc
Compression Ratio	11.5:1
Starter	Kick
Transmission	6-speed
Front Brake	Single disc
Rear Brake	Single disc
Front Tire	90/90-21
Rear Tire	140/80-18
Bore x Stroke	95.0 x 72.0 mm
Cooling system	Liquid cooled
Ignition	Digital
Frame	Steel
Rear Suspension	Monoshock
Category	Enduro / Off-road

Summary

Introduction to the Owner's Handbook

Serial Number Locations

Chassis and Engine Numbers

Locating and recording the motorcycle's chassis and engine identification numbers.

Clutch Lever Operation

Details on the clutch lever's function, adjustment, and operation.

Hand Decompression Lever

Explanation of the hand decompression lever's use and proper adjustment.

Hand Brake Lever

Information on the hand brake lever, its function, and adjustment screw.

Operation Instruments: Displays and Indicators

Digital Speedometer and Indicator Lamps (EXC)

Description of the digital speedometer, indicator lamps, and controls.

Digital Speedometer Function (EXC)

Explanation of the digital speedometer's display modes like trip, stopwatch, and clock.

Odometer Function (EXC USA)

Details on the odometer's mileage indication and reset function.

Speedometer and Indicator Lamps (EXC AUS)

Overview of the analog speedometer, mileage indicator, and warning lamps.

Short Circuit Button

Function of the short circuit button for engine shut-off.

Operation Instruments: Switches and Emergency Controls

Combination Switch Functions

Details on the combination switch for lights, horn, and engine shut-off.

Headlamp Switch (EXC USA)

Explanation of the headlamp switch operation on EXC USA models.

Flasher Switch

How to operate the flasher switch for turn signals.

Emergency OFF Button (EXC)

Operation of the emergency OFF button for engine shutdown.

Emergency OFF Switch (EXC Australia)

Function of the emergency OFF switch on EXC Australia models.

Operation Instruments: Fuel System Controls

Filler Cap and Breather Hose

Instructions for opening, closing, and installing the filler cap and breather hose.

Fuel Requirements and Safety

Information on recommended fuel type and safety precautions for refueling.

Fuel Tap Operation

Explanation of the fuel tap positions (OFF, ON, RES) and their functions.

Operation Instruments: Engine Starting Controls

Choke Operation

How to use the choke for cold starts and its deactivation.

Shift Lever and Gear Positions

Description of the shift lever, gear indication, and neutral position.

Kickstarter Operation

Instructions and safety warnings for using the kickstarter.

Foot Brake Pedal Adjustment

Details on adjusting the foot brake pedal position and free play.

Fork Compression Damping

Explanation of fork compression damping adjustment for ride comfort.

Operation Instruments: Suspension Adjustments

Fork Rebound Damping

How to adjust the fork's rebound damping for optimal suspension.

Shock Absorber Compression Damping

Instructions for adjusting the shock absorber's compression damping.

Shock Absorber Rebound Damping

Guide to adjusting the shock absorber's rebound damping.

Steering Lock Operation

How to lock the steering and important safety precautions.

Side Stand Operation

Proper use of the side stand and associated safety warnings.

Driving Instructions: Pre-Ride Checks and Initial Operation

Pre-Ride Checks

Essential checks to perform before every motorcycle ride for safety.

Initial Operation Instructions

Guidance for first-time riders to familiarize with the motorcycle.

Running-in Racing Models

Specific instructions for breaking in racing model engines.

Driving Instructions: Starting and Riding Procedures

Starting Engine Cold

Step-by-step guide for starting the engine when it's cold.

Starting Engine Warm

Procedure for starting the engine when it is already warm.

Engine Flooded Procedure

What to do if the engine is flooded, including starting steps.

Starting Off from Stationary

Correct procedure for setting off after starting the engine.

Shifting Gears and Riding

Guidance on gear shifting, throttle control, and efficient riding.

Driving Instructions: Safety, Braking, and Parking

Braking Techniques

Advice on using brakes, including special conditions and safety.

Stopping and Parking

Procedure for safely stopping the motorcycle and parking.

Side Stand Precautions

Important notes and warnings regarding the use of the side stand.

Maintenance: Clutch Lever and Steering Head Bearing

Adjusting Clutch Lever Position

How to adjust the clutch lever to an optimal position for comfort.

Checking and Adjusting Steering Head Bearing

Procedure for checking and adjusting the steering head bearing for play.

Maintenance: Front Fork and Handlebar

Front Fork Breather Plugs

Instructions for relieving excess pressure in the front fork.

Cleaning Telescopic Fork Dust Sleeves

How to clean the fork dust protection bellows and tubes.

Changing Handlebar Position

Guide to repositioning the handlebar for rider comfort.

Maintenance: Shock Absorber and Chain

Adjusting Shock Absorber Spring Preload

Procedure for adjusting the spring preload of the shock absorber.

Pivot Bearing Lubrication

Information on the pivot bearing's Teflon coating and non-lubrication.

Checking Chain Tension

How to check the chain tension and measure the slack.

Maintenance: Chain Adjustment and Wear

Correcting Chain Tension

Steps to adjust the chain tension and align the rear wheel.

Chain Maintenance Best Practices

Tips for cleaning and lubricating chains for longevity.

Checking Chain Wear

How to check for chain wear and when to replace it.

Maintenance: Disc Brakes and Front Brake Lever

KTM Disc Brake Information

General overview of brake calipers, pads, and discs.

Brake Fluid Reservoirs and Type

Information on brake fluid reservoirs and recommended fluid types.

Adjusting Front Brake Lever Free Travel

How to adjust the free travel of the front brake lever.

Maintenance: Front Brake Pad and Fluid Checks

Checking Front Brake Fluid Level

Procedure to check the brake fluid level in the front reservoir.

Refilling Front Brake Fluid Reservoir

Steps for refilling the front brake fluid reservoir with correct fluid.

Checking Front Brake Pads

Inspection guide for front brake pad lining thickness.

Replacing Front Brake Pads

Step-by-step instructions for replacing front brake pads.

Maintenance: Rear Brake Checks and Adjustment

Adjusting Foot Brake Pedal Position

How to adjust the basic position of the foot brake pedal.

Checking Rear Brake Fluid Level

Procedure to check the brake fluid level in the rear reservoir.

Refilling Rear Brake Fluid Reservoir

Steps for refilling the rear brake fluid reservoir.

Maintenance: Rear Brake Pads and Front Wheel Removal

Checking Rear Brake Pads

Inspection guide for rear brake pad lining thickness.

Replacing Rear Brake Pads

Step-by-step instructions for replacing rear brake pads.

Dismounting and Mounting Front Wheel

Procedure for removing and installing the front wheel.

Maintenance: Front and Rear Wheel Installation

Front Wheel Installation Details

Steps for correctly installing the front wheel and speedometer drive.

Dismounting and Mounting Rear Wheel

Procedure for removing and installing the rear wheel.

Maintenance: Tire Pressure and Spoke Tension

Tire Pressure Settings

Recommended tire air pressure for off-road and road use.

Checking Spoke Tension

Importance of spoke tension and how to check it.

Replacing Digital Speedometer Battery

Guide to replacing the battery in the digital speedometer.

Maintenance: Digital Speedometer Data Entry

Setting Total Mileage (DST)

Procedure to enter total mileage after battery replacement.

Setting Clock Time (CLK)

Procedure to set the clock time after battery replacement.

Maintenance: Wheel Circumference and Sensor Distance

Setting Wheel Circumference (WS)

How to set the wheel circumference for accurate speed readings.

Checking Magnetic Sensor Distance

Ensuring correct distance between magnet and sensor for speedometer.

Maintenance: Battery and Charging

Battery Care and Removal

Information on battery maintenance, removal, and replacement.

Charging the Battery

Instructions and guidelines for safely charging the motorcycle battery.

Maintenance: Fuses and Headlight Lamp

Fuse Identification and Replacement

Location and replacement of fuses in the electrical system.

Replacing Headlight Lamp (H4)

Step-by-step guide for replacing the H4 headlight bulb.

Maintenance: Cooling System Checks and Bleeding

Cooling System Overview

Description of the cooling system's components and operation.

Checking Coolant Level

Procedure for checking the coolant level and safety warnings.

Bleeding the Cooling System

Instructions for draining and bleeding air from the cooling system.

Maintenance: Air Filter and Silencer Packing

Cleaning the Air Filter

Procedure for cleaning the air filter to maintain performance.

Replacing Silencer Glass Fiber Packing

Guide for replacing the glass fiber yarn packing in the silencer.

Cleaning Spark Arrestor (EXC USA)

How to clean the spark arrestor on EXC USA models.

Maintenance: Clutch Hydraulics and Cables

Adjusting Decompression Cable

How to adjust the hand decompression release cable for proper play.

Adjusting Throttle Cables

Procedure for adjusting throttle cables and ensuring smooth operation.

Checking Hydraulic Clutch Oil Level

How to check the oil level in the hydraulic clutch master cylinder.

Bleeding Hydraulic Clutch System

Steps for bleeding air from the hydraulic clutch system.

Maintenance: Carburetor Adjustment and Checks

Carburetor Idling Adjustment

How to adjust the engine's idling speed for optimal starting.

Carburetor Wear Information

Details on wear of carburetor parts and replacement intervals.

Mixture Control Screw Adjustment

Procedure for adjusting the mixture control screw, especially on EXC models.

Checking Carburetor Float Level

How to measure and adjust the float level in the carburetor.

Maintenance: Carburetor Draining and Engine Oil Circuit

Draining Carburetor Float Chamber

Procedure for draining water from the carburetor float chamber.

Engine Oil Circuit Overview

Description of the engine oil flow through the lubrication system.

Checking Engine Oil Level

How to check the engine oil level in warm and cold states.

Maintenance: Engine Oil Specifications and Change

Engine Oil Type and Quality

Recommended engine oil types and quality requirements.

Changing Engine Oil Procedure

Step-by-step guide for changing the engine oil and cleaning screens.

Maintenance: Changing Oil Filters

Procedure for Changing Oil Filters

Instructions for removing and installing the oil filter inserts.

Troubleshooting Engine Starting Issues

Engine Does Not Crank (E-Starter)

Causes and remedies for the engine not cranking with the e-starter.

Engine Cranks But Does Not Start

Troubleshooting for engines that crank but don't start.

Engine Fails to Idle

Causes and solutions for the engine failing to idle properly.

Troubleshooting Engine Performance Issues

Engine Does Not Rev High

Causes and remedies for the engine not reaching high RPMs.

Engine Will Not Reach Full Power

Troubleshooting for loss of engine power.

Engine Stops or Splutters

Diagnosing and fixing engine stopping or sputtering issues.

Engine Overheating

Causes and solutions for the engine getting too hot.

High Oil Consumption

Troubleshooting excessive engine oil consumption.

Electrical System Issues

Diagnosing problems with lamps, horn, or battery discharge.

Cleaning, Winterization, and Storage Procedures

Motorcycle Cleaning Guidelines

Best practices for cleaning the motorcycle's plastic surfaces.

Conservation for Winter Operation

Precautions for riding and storing the motorcycle in winter.

Motorcycle Storage Instructions

Steps to take when storing the motorcycle for extended periods.

Re-initiation After Storage

Procedure for preparing the motorcycle after a storage period.

Technical Data: Engine Specifications

Engine Specifications Overview

Detailed specifications for the engine, including displacement and bore/stroke.

Basic Carburetor Settings

Standard settings for the carburetor, including jet sizes and needle positions.

Tightening Torques Specifications

Engine Component Tightening Torques

Torque specifications for various engine case and cover screws.

Engine Oil Recommendations

Guidelines for selecting and using appropriate engine oil.

Technical Data: Chassis Specifications

Chassis Specifications Overview

Detailed specifications for the frame, forks, brakes, and wheels.

Standard Fork Adjustment Settings

Standard settings for compression and rebound damping on the fork.

Chassis Component Tightening Torques

Torque specifications for chassis components like wheels and suspension.

Standard Shock Absorber Adjustment

Standard settings for shock absorber compression and rebound.

Wiring Diagram and Component Identification

Wiring Diagram Components (USA)

List of electrical components and their corresponding numbers in the wiring diagram.

Wiring Diagram Schematics (Europe)

Wiring Diagram Schematics

Schematic representation of the motorcycle's electrical system.

Wiring Diagram Component Cross-Reference

Component Identification List

Cross-reference list of electrical components in multiple languages.

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KTM 520 EXC RACING 2000 User Manual

Table of Contents

Questions and Answers:

KTM 520 EXC RACING 2000 Specifications

Summary

Introduction to the Owner's Handbook

Serial Number Locations

Chassis and Engine Numbers

Clutch Lever Operation

Hand Decompression Lever

Hand Brake Lever

Operation Instruments: Displays and Indicators

Digital Speedometer and Indicator Lamps (EXC)

Digital Speedometer Function (EXC)

Odometer Function (EXC USA)

Speedometer and Indicator Lamps (EXC AUS)

Short Circuit Button

Operation Instruments: Switches and Emergency Controls

Combination Switch Functions

Headlamp Switch (EXC USA)

Flasher Switch

Emergency OFF Button (EXC)

Emergency OFF Switch (EXC Australia)

Operation Instruments: Fuel System Controls

Filler Cap and Breather Hose

Fuel Requirements and Safety

Fuel Tap Operation

Operation Instruments: Engine Starting Controls

Choke Operation

Shift Lever and Gear Positions

Kickstarter Operation

Foot Brake Pedal Adjustment

Fork Compression Damping

Operation Instruments: Suspension Adjustments

Fork Rebound Damping

Shock Absorber Compression Damping

Shock Absorber Rebound Damping

Steering Lock Operation

Side Stand Operation

Driving Instructions: Pre-Ride Checks and Initial Operation

Pre-Ride Checks

Initial Operation Instructions

Running-in Racing Models

Driving Instructions: Starting and Riding Procedures

Starting Engine Cold

Starting Engine Warm

Engine Flooded Procedure

Starting Off from Stationary

Shifting Gears and Riding

Driving Instructions: Safety, Braking, and Parking

Braking Techniques

Stopping and Parking

Side Stand Precautions

Maintenance: Clutch Lever and Steering Head Bearing

Adjusting Clutch Lever Position

Checking and Adjusting Steering Head Bearing

Maintenance: Front Fork and Handlebar

Front Fork Breather Plugs

Cleaning Telescopic Fork Dust Sleeves

Changing Handlebar Position

Maintenance: Shock Absorber and Chain

Adjusting Shock Absorber Spring Preload

Pivot Bearing Lubrication

Checking Chain Tension

Maintenance: Chain Adjustment and Wear

Correcting Chain Tension

Chain Maintenance Best Practices

Checking Chain Wear

Maintenance: Disc Brakes and Front Brake Lever

KTM Disc Brake Information

Brake Fluid Reservoirs and Type

Adjusting Front Brake Lever Free Travel

Maintenance: Front Brake Pad and Fluid Checks

Checking Front Brake Fluid Level

Refilling Front Brake Fluid Reservoir

Checking Front Brake Pads

Replacing Front Brake Pads

Maintenance: Rear Brake Checks and Adjustment

Adjusting Foot Brake Pedal Position

Checking Rear Brake Fluid Level