New and Improved! 2002 KTMs

Quality, Performance, and Innovation

Feb. 01, 2006 By ORC STAFF
» 2002 KTM 520 SX
200 E/XC
250 E/XC
300 E/XC
380 E/XC
400 E/XC
520 E/XC


  • New O-ring seal on the countershaft
  • Reinforced ignition and clutch covers are stronger and more resistant to crash damage.


  • New fiber drive plates with more contact area to the basket decrease notching of the basket.
  • Thicker steel disks increase heat dissipation.

Camshaft and Water Pump

  • New sealed ball bearing on the camshaft is more resistant to contamination and wear.
  • Newly designed water pump seal carrier.

Front Forks

  • New 48 mm USD forks.
  • More rigid.
  • Derived from the "WORKS" fork.
  • Equipped with external preload adjusters (one on each side).

Shock Absorbers (WP)

  • Adjustable high and low speed compression damping.
  • More shaft travel.
  • Upper shock body is now forged instead of cast.
  • New valving.


  • Bigger, Badder, Better Bolt.


  • Improved design at the rear axle mounts.
  • Minimizes flex and twisting of the entire swingarm and improves overall performance.

Graphic Design

  • Seat is still two-toned, but with a new manufacturing process.
  • Rear fender and side panel are BLACK.
  • Spoiler, light mask, and front fender are ORANGE.
  • Spoiler logo is the same as 2001 but with more wear resistance.


520 SX Racing
ENGINE single cylinder, 4-stroke
Displacement 510.4 cc
Bore x stroke 95 / 72 mm
Compression ratio 11:1
Starter kick starter
Transmission 4 gears, close ratio
Fuel Premium Fuel (92 + U.S. Octane)
Carburetor Keihin MX FCR 39
Control 4 V / OHC with roller rocker lever
Lubrication pressure lubrication with 2 Eaton pumps
Engine oil / transmission lubrication 2 stroke 10w-40
Primary ratio 33 : 76
Final drive X-Ring Chain 5/8 x 1/4" 520 VM
Cooling liquid cooled
Clutch wet multi-disc clutch, operated hydraulically
Ignition Kokusan digital 4K-3B
Spark plug NGK CR8 EK
Frame chromium molybdenum
Subframe Aluminum
Handlebar conical MAGURA
Front suspension WP-USD 48 MA DA
Rear suspension WP-PDS-shock absorber DA
Suspension travel front/rear 295 / 320 mm (11.6 inches/12.6 inches)
Front brake disc brake 260 mm
Rear brake disc brake 220 mm
Front / rear rim 1.6 x 21"; 2.15 x 19" Excel
Front / rear tire 80/100-21"; 110/90-19"
Final drive ratio 14:48
Main silencer Aluminum
Steering head angle 26.5°
Wheel caster / trail approx. 112 mm / 4.40 inches
Wheelbase 1481mm / 58.3 inches
Ground clearance 380mm / 15 inches
Seat height (unladened) 925 mm / 36.4 inches
Fuel capacity approx. 7 liters / 1.9 U.S. Gallons
Weight approx. 107 kgs / 236 lbs. Newsletter
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