How to Change the Oil in a 2000 KTM 520 EXC

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Regular oil changes are crucial for the performance and longevity of your 2000 KTM 520 EXC. The process is straightforward, but this model’s RFS engine uses a dual oil screen system which demands careful attention to detail. Below you’ll find a step-by-step guide, tools required, and specific call-outs for this make and model. All instructions are proprietary to MotoSport.com.

Tools and Materials Needed

  • Drain pan – Large enough to hold at least 2 quarts of oil
  • 13mm socket and ratchet or box wrench – For the primary drain plug
  • 8mm socket or Allen wrench – For screen plugs
  • Torque wrench – To ensure proper reinstallation tightness
  • Funnel
  • Service manual
  • Contact cleaner and paper towels
  • Oil filter(s) – Two filters (short and long), confirm compatibility with your year/model
  • New copper crush washers (recommended)
  • Engine oil – 10W-50 full synthetic or as specified by KTM (about 1.7 quarts)
  • Gloves and rags

Key Model-Specific Call-outs for the 2000 KTM 520 EXC

  • This bike uses the KTM RFS (Racing Four-Stroke) engine, which features two oil filters and two oil screens. Both need to be serviced at every oil change.
  • The engine must be warmed up prior to draining – let it idle for a few minutes to ensure the oil flows well.
  • The main drain plug is a 13mm bolt under the engine, horizontally mounted. Some owners report it may be on very tight; make sure you use the correct tool to avoid stripping, and consider using a breaker bar with caution.
  • Oil screens: There’s a long screen under the shifter (left side) and a short screen beneath the engine (bottom). Both must be cleaned along with replacing the filters.
  • If a skid plate is fitted, it usually does not need to be removed, but check that the drain and screen plugs are accessible.
  • Always inspect the removed screens and magnetic drain plug for metallic debris—a sign of internal wear.
  • If fasteners seem seized, a brief application of controlled heat or a few taps with a hammer can help loosen (do not overdo this).

Step-by-Step Oil Change Procedure

  • Warm Up the Engine
    Start the motorcycle and let it idle for 3–5 minutes, then switch it off and set it upright on a stand.
  • Remove the Filler Cap
    Unscrew the oil filler cap to allow the oil to drain more freely.
  • Drain the Oil
    • Place your drain pan beneath the engine’s main drain plug.
    • Using a 13mm wrench, carefully loosen and remove the main drain plug (it’s horizontally mounted under the engine).
    • Let the oil fully drain. While it's draining, inspect the magnetic tip for metal shavings and clean it off.
  • Remove and Clean Oil Screens
    • Locate the long oil screen plug under the shifter on the left side of the engine (use an 8mm Allen or socket wrench to remove).
    • Extract the screen; clean it with contact cleaner and inspect for debris.
    • Locate the short oil screen plug at the bottom of the engine; repeat the cleaning process.
    • Replace the O-rings or copper washers if they appear worn.
  • Replace Oil Filters
    • There are two oil filters on the RFS engine – both accessible from the right side of the bike, covered by small bolted-on covers.
    • Remove filter covers, then extract the used filters. Compare new and old filters to confirm fitment before installing.
    • Install new filters, making sure they are oriented correctly per your manual.
    • Inspect and, if needed, replace the cover gaskets or O-rings.
  • Reinstall Screens and Drain Plug
    • Clean the threads of all plugs and apply a small amount of fresh oil to the new crush washers.
    • Reinstall screens and plugs. Hand-tighten first, then torque to specification (check the manual; usually around 10–15 ft-lbs for screens and the drain plug).
  • Add Fresh Oil
    • Use a funnel to pour in about 1.7 quarts (1.6 liters) of 10W-50 synthetic engine oil or as specified for your climate and riding conditions.
    • Reinstall the filler cap.
  • Check for Leaks and Oil Level
    • Start the bike and let it idle for a minute, then shut off and inspect all plugs and filters for leaks.
    • Check the oil level with the dipstick; top off if necessary.

Additional Tips for the 2000 KTM 520 EXC

  • The oil change interval should be every 10–15 hours of riding for racing or high-stress use, or up to 30 hours for light trail use.
  • Always use premium 95-octane gasoline or higher for best performance and long engine life.
  • Dispose of used oil and filters responsibly at a designated recycling facility.

Summary

Oil changes on the 2000 KTM 520 EXC are relatively simple but thorough, thanks to the dual filter and dual oil screen design. Always refer to your service manual for the latest torque specs and part numbers. Keeping up on this maintenance step ensures the legendary performance that KTM’s RFS engines are known for.

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Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.