Home
Basic Dirt Bike How-To's - Video
Dirt Bike How-To's - Video
Living The Moto Life - Video
Bike Tests | Shoot-Outs - Video
Forums
What's new
Latest activity
Log-In
Join
What's new
Menu
Log-In
Join
Navigation
Install the app
Install
More options
Close Menu
Forums
Dirt Bike Discussions By Brand
KTM MX & Off-Road Dirt Bikes
Nitpicking '02 520SX
Reply to thread
JavaScript is disabled. For a better experience, please enable JavaScript in your browser before proceeding.
You are using an out of date browser. It may not display this or other websites correctly.
You should upgrade or use an
alternative browser
.
Message
[QUOTE="MrCyberdude, post: 1468934, member: 24474"] This site is down but I can post the old info here 2002KTM400exc .1 week old. Differences from 2001 It has been fun running it in during the week. Ok according to the supplied parts manual the new parts are for the 400/520 SX, MX, EXC RACING The info is for all in range unless a model is mentioned And if it is wrong then u should be writing this for others, instead of me. All the info was added to help people maybe improve on their bike setup and to maybe see what has been hopefully improved upon thereby highlighting possible weaknesses. And here they are! I may have missed some or errored! 2002 updates to the KTM 400/520 range --ENGINE CASE-- Sprocket cover racing (plastic cover) and new mounting bush oil plug M24x3 Engine breather tube - --CRANKSHAFT,PISTON-- same - --BALANCER SHAFT-- same - --CYLINDER & CYLINDER HEAD-- same - --VALVE DRIVE-- Rocker arm intake Rocker arm exhaust - --TIMING VALVE-- Between the camshaft-gear and the water pump Washer Gasket support O ring - --LUBRICATING SYSTEM-- same - --CARBURETOR-- Carburetor Keihin CR39 (20 new parts many are as needed ie diff jets) also called Vergaser Keihin SX FCR 39 jets, screws, links and engine breather tube - --IGNITION SYSTEM KOKUSAN 4K3A(400sx) or 4K3B(400/520) same - --ELECTRIC STARTER-- same - --CLUTCH-- Inner clutch hub racing 4x Intermediate disc 1.4mm Pressure bolt 6x AH screws to hold pressure cap and hub but same springs 4x Intermediate disc 1.0mm 12x driving sleeves d=8, l=31 Same 7x lining disc 1.8mm - --KICKSTARTER-- same - --TRANSMISSION 6 GEAR & 4 gear(520sx) same - --TRANSMISSION II (400/520exc),(400sx mxc),(520sx)-- 3x Divided needle bearing.k 22x26x10 for the idler gears Sprocket screw and spring washer Shaft seal ring 32x45x7 - --SHIFTING MECHANISM-- AH screw m6x30 that mounts the shift locating drum to the shift roller 6 speed gear(dog clutch) - --COOLING SYSTEM-- MXC only has a bush, roller and screw for spoiler and tank - --SPECIAL TOOLS-- And this doesnt make much sense to me but a new Piston ring compressor D=75mm ??? and the other 2 of 89mm and 95 are there as ususal.? - * * * GOD I NEED A BREAK!! I HOPE YOU ALL APPRECIATE THIS ? * * *NOW FOR THE FRAME/CHASSIS* This will be less detailed - --FRONT FORK WHITE POWER USD-- i don't know what was on 2001 but for 2002 Front Rebound Dampening knob on top -REAR- My manual says WP-5018 PDS on rear and the SX has High Speed compression adj, but not on EXC The SX has Spring PDS7-260, EXC PDS6-260 ie exc softer than sx -FRONT- 400/520 SX WhitePower 48mm WP-4860-MXMA and new bottom tripple clamp and axle about 30 different bits(size) - 400/530 EXC WhitePower 43mm WP-4357-MXMA - --HANDLEBAR, CONTROLS-- fuel hose 7x2mm ??? glue ??? on throttle maybe?? SX short circuit button as usual, comes with 2 mirrors and the mirror comes with a bracket that can be used if you break the original bracket clamp. - --FRAME-SUBFRAME-- SX silver sx racing footpegs SX instead of chain roller a sliding piece is used - --SIDE STAND-- Side stand screw Side stand bracket aus/eu version has the small bracket and 2nd spring - --SWINGARM, CHAIN GUARD-- same - --REAR BRAKE CONTROL-- self-locking nut & washer for pivot bolt - --EXHAUST TUBE-- same - --EXHAUST MUFFLER-- All new SX silencer 595.05.079.200 EXC 400 unthrottled 595.05.081.100 is avail EXC 520 unthrottled 595.05.081.300 is avail EXC 400 throttled 595.05.081.000 EXC 520 throttled 595.05.081.400 MXC EXC RACING USA 250-520 sparky 595.05.082.200 EXC 400 end cap unthrottled 595.05.081.150 is avail EXC 400 end cap throttled 30mm 595.05.081.050 there are more but these are the NEW ones - --AIR FILTER BOX-- same - --TANK SEAT COVER-- gasket for filler cap high SX seat 125/250/380sx SX seat cover Side covers black EXC washer for tank roller - --MASK, FENDERS-- Black rear fender All new decal sets (front and rear) sides - --FRONT WHEEL & BRAKES-- SX 20mm axle & nut for 48mm forks - --REAR WHEEL & BRAKE-- Bearing spacer 121.5mm - --HEADLIGHT & TAILLIGHT-- rear light locknuts & washers - --SPEEDOMETER-- washer for locknut only for the square USA EXC - --WIRING HARNESS-- same for all except horn 12V K80/L - --ACCESSORIES-- There are 2 new ones Hand Guards 600.02.079.000/30 avail Engine Protection Plastic 590.03.090.200 avail - - - - Thankfully all that is over. As many of you can imagine how long that took it would be good to see some other people add to this bulletin board to help others out. - [URL="http://www.users.bigpond.net.au/Mr2"]www.users.bigpond.net.au/Mr2[/URL] - - =========================================================================== =========================================================================== Primary ratio for all is 33:76 ====================== --- 400sx - 400mxc - 400exc - 520sx - 520mxc - 520exc 1 - 16:32 -- 16:32 -- 14:34 -- 16:32 -- 16:32 -- 14:34 2 - 18:30 -- 18:30 -- 17:31 -- 18:30 -- 18:30 -- 17:31 3 - 20:28 -- 20:28 -- 19:28 -- 20:28 -- 20:28 -- 19:28 4 - 22:26 -- 22:26 -- 22:26 -- 22:26 -- 22:26 -- 22:26 5 - 24:24 -- 24:24 -- 24:23 -- --N/A- -- 24:24 -- 24:23 6 - 21:18 -- 21:18 -- 26:21 -- --N/A- -- 21:18 -- 26:21 My 2002 KTM 400exc aus sprockets were dumped and replaced with 14:52 the day I got it. This goes well. but I am considering a 13 for the hills thick with trees for those nervous moments. I was also given the option of having the exhaust dismantled and internally modified but I opted to wait until after I had run it in, but I have since decided it has plenty of power for the steep hills I attack. My problem is getting a knobbie that grips and flings enough clay out. I could knock the guts out and I would have no probs as its a few pop rivets and no one would know I've been in, if i was booked for noise i could just pack it to the max with fibre glass intill i pass the complience test. The Horse Power MODs i have been recommended to me are as follows. (and they are in the AU August Dirt Action Mag) 1. OIL level, keep in window when hot (higher severly robs power) $0au 2. AIRBOX drill holes and place mesh in side airbox cover. $5au (Not for me) 3. Exhaust End Cap Change $140au 4. ReJet / Tune $0-100 Suggestions-Leave it as is or buy the KTM 520 then complain there is too much power. But thats just my opinion, and until you can follow me where i go - I'M RIGHT { [/QUOTE]
Verification
Which ocean is California closest to?
Post reply
Forums
Dirt Bike Discussions By Brand
KTM MX & Off-Road Dirt Bikes
Nitpicking '02 520SX
This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
By continuing to use this site, you are consenting to our use of cookies.
Accept
Learn more…
Top
Bottom